Operators and Safety Manual

Model
8042
S/N 9909 THRU 13197
8990360C
MARCH 2004

ANSI

Operators and Safety Manual

Model
8042
S/N 9909 THRU 13197
8990360C
MARCH 2004

ANSI
 WARNING
IMPROPER 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 YOU
OPERATE 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 known

to the State of California to cause cancer, birth defects, and
other reproductive harm.

WARNING
IMPROPER 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 YOU
OPERATE 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 known

to the State of California to cause cancer, birth defects, and
other reproductive harm.
 Table Of Contents
Introduction Jump Starting ............................. 28 6. Engine Fan Belt Check ......... 66
The Manual .................................. 2 Operating ................................... 29 7. Hydraulic Oil and Filter ......... 67
Replacement Parts ....................... 2 Stabil-TRAK™ System Test ....... 36 8. Transmission Oil and Filter ... 70
Reports ......................................... 2 Using The Capacity Chart .......... 39 9. Axle Oil ................................. 72
Disclaimer .................................... 2 Fork Ratings ............................... 42 10. Wheel End Oil ....................... 73
How To Pick, Carry 11. Wheels and Tires .................. 75
& Place a Load ......................... 44 12. Battery .................................. 76
Safety Practices Elevating Personnel ................... 44 13. Fuse and Relay
Hazard Classification System ....... 3 Using Other Attachments ........... 46 Replacement ........................ 78
New or Additional Operators ........ 4 Shut-Off ...................................... 47 14. Boom Chains & Wear Pads .. 80
Personal Considerations .............. 4 Towing and Tie Down ................. 47 15. Emergency Boom Lowering .. 86
Operational Considerations .......... 7 16. Emergency Brake Test ......... 93
Equipment Considerations ......... 11
General Maintenance
Routine Equipment Checklist ..... 48 Specifications
Operation Warning Decal Locations ........... 49 Fluid and Lubricant Capacities ... 94
Controls ...................................... 12 Maint. Schedule and Checklist ... 50 Tires ........................................... 95
Instruments and Indicators ......... 19 1. Lubrication Points ................. 54 Engine ........................................ 96
Optional Controls........................ 23 2. Air Cleaner and Weights ...................................... 96
Walk-Around Inspection ............. 25 Restriction Indicator.. ............ 55 Vehicle Dimensions .................... 96
Normal Starting .......................... 25 3. Engine Cooling System ........ 58 Electrical System ........................ 96
Cold Starting .............................. 26 4. Engine Oil and Filter ............. 60 Stability Tipping Limits ................ 97
5. Engine Fuel System.............. 62

8042 Rev 3/04 © 2004 JLG Industries, Inc. Page 1

Table Of Contents
Introduction Jump Starting ............................. 28 6. Engine Fan Belt Check ......... 66
The Manual .................................. 2 Operating ................................... 29 7. Hydraulic Oil and Filter ......... 67
Replacement Parts ....................... 2 Stabil-TRAK™ System Test ....... 36 8. Transmission Oil and Filter ... 70
Reports ......................................... 2 Using The Capacity Chart .......... 39 9. Axle Oil ................................. 72
Disclaimer .................................... 2 Fork Ratings ............................... 42 10. Wheel End Oil ....................... 73
How To Pick, Carry 11. Wheels and Tires .................. 75
& Place a Load ......................... 44 12. Battery .................................. 76
Safety Practices Elevating Personnel ................... 44 13. Fuse and Relay
Hazard Classification System ....... 3 Using Other Attachments ........... 46 Replacement ........................ 78
New or Additional Operators ........ 4 Shut-Off ...................................... 47 14. Boom Chains & Wear Pads .. 80
Personal Considerations .............. 4 Towing and Tie Down ................. 47 15. Emergency Boom Lowering .. 86
Operational Considerations .......... 7 16. Emergency Brake Test ......... 93
Equipment Considerations ......... 11
General Maintenance
Routine Equipment Checklist ..... 48 Specifications
Operation Warning Decal Locations ........... 49 Fluid and Lubricant Capacities ... 94
Controls ...................................... 12 Maint. Schedule and Checklist ... 50 Tires ........................................... 95
Instruments and Indicators ......... 19 1. Lubrication Points ................. 54 Engine ........................................ 96
Optional Controls........................ 23 2. Air Cleaner and Weights ...................................... 96
Walk-Around Inspection ............. 25 Restriction Indicator.. ............ 55 Vehicle Dimensions .................... 96
Normal Starting .......................... 25 3. Engine Cooling System ........ 58 Electrical System ........................ 96
Cold Starting .............................. 26 4. Engine Oil and Filter ............. 60 Stability Tipping Limits ................ 97
5. Engine Fuel System.............. 62

8042 Rev 3/04 © 2004 JLG Industries, Inc. Page 1

Introduction IMPORTANT!
The replacement of any part on this product by anything
The Manual other than a JLG authorized replacement part may ad-
versely affect the performance, durability, or safety of this
This Owners/Operator’s manual provides the information
product and will void the warranty. JLG assumes no liability
you need to correctly operate and maintain this vehicle.
for unauthorized replacement parts which adversely affect
IMPORTANT! Before you operate this vehicle, read this the performance, durability or safety of this product.
manual completely and carefully so you will understand the
safety instructions and the operation of the controls and
safety equipment. You must comply with all Danger, Reports
Warning, and Caution notices. They are for your benefit.
All reference to the right side, left side, front, or rear are given IMPORTANT!
from the operator's seat looking in a forward direction. A Warranty Registration form must be filled out by the Sky
Trak distributor, signed by the purchaser, and returned to
JLG Industries, Inc. is hereinafter referred to as JLG.
JLG once the product is sold and/or put into service. This
Replacement Parts report activates the warranty period, assuring that your
claims during the warranty period will be honored and
For your easy reference when processed expediently. To guarantee you full warranty
ordering replacement parts or MODEL & SERIAL service, make sure your distributor has returned the
NUMBERS
making service inquiries on business reply card of this form to JLG.
this machine, record its model
and serial numbers on the
back cover of the manual. Disclaimer
The numbers are stamped on
the serial number plate which JLG reserves the right to make changes on and to add
is located on the front of the improvements upon its products at any time without public
machine's frame tilt cylinder notice or obligation. JLG also reserves the right to discon-
tower. OH0280
tinue manufacturing any product at its discretion at any time.

Page 2 8042 Rev 3/04

Introduction IMPORTANT!
The replacement of any part on this product by anything
The Manual other than a JLG authorized replacement part may ad-
versely affect the performance, durability, or safety of this
This Owners/Operator’s manual provides the information
product and will void the warranty. JLG assumes no liability
you need to correctly operate and maintain this vehicle.
for unauthorized replacement parts which adversely affect
IMPORTANT! Before you operate this vehicle, read this the performance, durability or safety of this product.
manual completely and carefully so you will understand the
safety instructions and the operation of the controls and
safety equipment. You must comply with all Danger, Reports
Warning, and Caution notices. They are for your benefit.
All reference to the right side, left side, front, or rear are given IMPORTANT!
from the operator's seat looking in a forward direction. A Warranty Registration form must be filled out by the Sky
Trak distributor, signed by the purchaser, and returned to
JLG Industries, Inc. is hereinafter referred to as JLG.
JLG once the product is sold and/or put into service. This
Replacement Parts report activates the warranty period, assuring that your
claims during the warranty period will be honored and
For your easy reference when processed expediently. To guarantee you full warranty
ordering replacement parts or MODEL & SERIAL service, make sure your distributor has returned the
NUMBERS
making service inquiries on business reply card of this form to JLG.
this machine, record its model
and serial numbers on the
back cover of the manual. Disclaimer
The numbers are stamped on
the serial number plate which JLG reserves the right to make changes on and to add
is located on the front of the improvements upon its products at any time without public
machine's frame tilt cylinder notice or obligation. JLG also reserves the right to discon-
tower. OH0280
tinue manufacturing any product at its discretion at any time.

Page 2 8042 Rev 3/04

Safety Practices
The information in this manual does not replace any
OL3231
safety rules and laws used in your area. Before operating
this telescopic handler, learn the rules and laws for your The signal word “DANGER” indicates an imminently
area. Make sure the vehicle has the correct equipment hazardous situation which, if not avoided, will result in
according to these rules and laws. death or serious injury.
Your safety and the safety of others in the work area
depend significantly upon your knowledge and under-
standing of all correct operating practices and procedures ON0030
for this vehicle.
The signal word “WARNING” indicates a potentially
Hazard Classification System hazardous situation which, if not avoided, could result in
death or serious injury.

OP0330

This safety alert symbol is used with the following signal ON0010
words to attract your attention to messages found within the The signal word “CAUTION” indicates a potentially
manual and on safety decals located on the vehicle. They hazardous situation which, if not avoided, may result in
are reproduced herein and pertain to proper operation and minor or moderate injury.
procedure messages contained throughout the manual. The
message that follows the symbol contains important infor-
mation about Safety. To avoid possible injury or death,
carefully read and follow the messages! Be sure to fully OS2020

understand the potential causes of injury or death. The signal word “CAUTION” used without the safety alert
Signal Word: A distinctive word used throughout this symbol indicates a potentially hazardous situation which, if
manual that alerts the reader to the existence and relative not avoided, may result in property damage.
degree of the hazard on or near the vehicle.

8042 Rev 3/04 Page 3

Safety Practices
The information in this manual does not replace any
OL3231
safety rules and laws used in your area. Before operating
this telescopic handler, learn the rules and laws for your The signal word “DANGER” indicates an imminently
area. Make sure the vehicle has the correct equipment hazardous situation which, if not avoided, will result in
according to these rules and laws. death or serious injury.
Your safety and the safety of others in the work area
depend significantly upon your knowledge and under-
standing of all correct operating practices and procedures ON0030
for this vehicle.
The signal word “WARNING” indicates a potentially
Hazard Classification System hazardous situation which, if not avoided, could result in
death or serious injury.

OP0330

This safety alert symbol is used with the following signal ON0010
words to attract your attention to messages found within the The signal word “CAUTION” indicates a potentially
manual and on safety decals located on the vehicle. They hazardous situation which, if not avoided, may result in
are reproduced herein and pertain to proper operation and minor or moderate injury.
procedure messages contained throughout the manual. The
message that follows the symbol contains important infor-
mation about Safety. To avoid possible injury or death,
carefully read and follow the messages! Be sure to fully OS2020

understand the potential causes of injury or death. The signal word “CAUTION” used without the safety alert
Signal Word: A distinctive word used throughout this symbol indicates a potentially hazardous situation which, if
manual that alerts the reader to the existence and relative not avoided, may result in property damage.
degree of the hazard on or near the vehicle.

8042 Rev 3/04 Page 3

 New or Additional Operators 3. Dismounting
At the time of original purchase, the purchaser of this
vehicle was instructed by the seller on its safe and correct
use. If this vehicle is to be used by an employee or is
loaned, rented or sold to someone other than the pur-
chaser, make certain that the new operator reads and
understands the Operator’s Manual and the Rough
Terrain Forklift Safety Manual that are provided with the
vehicle before operating the vehicle.

In addition, make sure that the new operator has com-

pleted a walk-around inspection of the vehicle, is familiar
with all decals and safety equipment on the vehicle, and
has demonstrated the correct use of all controls.

Personal Considerations OG0400

DO NOT get off the vehicle until you:

1. Seat Belt • place the travel select lever in (N) NEUTRAL,
Always adjust the seat and fasten the seat belt • move neutral lock lever to NEUTRAL LOCK
securely before you start the engine. position,
• engage the emergency brake switch,
2. Clothing and Safety Gear • lower the boom,
DO NOT wear loose clothing or jewelry that can get • ground the carriage,
caught on controls or moving parts. Wear the • turn engine off,
protective clothing and personal safety gear issued • unbuckle the seat belt, and
or called for by job conditions. • exit the vehicle using the hand holds.

Page 4 8042 Rev 3/04

New or Additional Operators 3. Dismounting

At the time of original purchase, the purchaser of this
vehicle was instructed by the seller on its safe and correct
use. If this vehicle is to be used by an employee or is
loaned, rented or sold to someone other than the pur-
chaser, make certain that the new operator reads and
understands the Operator’s Manual and the Rough
Terrain Forklift Safety Manual that are provided with the
vehicle before operating the vehicle.

In addition, make sure that the new operator has com-

pleted a walk-around inspection of the vehicle, is familiar
with all decals and safety equipment on the vehicle, and
has demonstrated the correct use of all controls.

Personal Considerations OG0400

DO NOT get off the vehicle until you:

1. Seat Belt • place the travel select lever in (N) NEUTRAL,
Always adjust the seat and fasten the seat belt • move neutral lock lever to NEUTRAL LOCK
securely before you start the engine. position,
• engage the emergency brake switch,
2. Clothing and Safety Gear • lower the boom,
DO NOT wear loose clothing or jewelry that can get • ground the carriage,
caught on controls or moving parts. Wear the • turn engine off,
protective clothing and personal safety gear issued • unbuckle the seat belt, and
or called for by job conditions. • exit the vehicle using the hand holds.

Page 4 8042 Rev 3/04

4. Chemical Hazards • DO NOT use your hand to check for leaks.
Use a piece of cardboard or paper to search
A. Exhaust Fumes
for leaks. Wear gloves to protect hands from
Fumes from the engine exhaust can cause spraying fluid.
injury or death. If operating in an enclosed • Hydraulic fluid can cause permanent eye
area, provide good ventilation to replace injury. Wear appropriate eye protection and
hazardous exhaust fumes with fresh air. stop engine and relieve pressure before
B. Explosive Fuel disconnecting lines.
Engine fuel is flammable and can cause a fire • If anyone is injured by or if any hydraulic fluid
and/or an explosion. Avoid danger by keeping is injected into the skin, obtain medical
sparks, open flames and smoking materials attention immediately or gangrene may result.
away from vehicle and fuel during refueling or D. Battery
fuel system servicing. Know where fire extin-
guishers are kept on the worksite and how to The following WARNING is intended to supple-
use them. ment and does not replace the warnings and
information provided on the battery by the
C. Hydraulic Fluid battery manufacturer.
• DO NOT attempt to repair or tighten any
hydraulic hoses or fittings while the engine is
running or when the hydraulic system is under
pressure. Fluid in the hydraulic system is
under enough pressure that it can penetrate
the skin causing serious injury or death.
• HOT HYDRAULIC FLUID WILL CAUSE
SEVERE BURNS. Wait for fluid to cool down
before disconnecting lines.
OG0360

8042 Rev 3/04 Page 5

4. Chemical Hazards • DO NOT use your hand to check for leaks.

Use a piece of cardboard or paper to search
A. Exhaust Fumes
for leaks. Wear gloves to protect hands from
Fumes from the engine exhaust can cause spraying fluid.
injury or death. If operating in an enclosed • Hydraulic fluid can cause permanent eye
area, provide good ventilation to replace injury. Wear appropriate eye protection and
hazardous exhaust fumes with fresh air. stop engine and relieve pressure before
B. Explosive Fuel disconnecting lines.
Engine fuel is flammable and can cause a fire • If anyone is injured by or if any hydraulic fluid
and/or an explosion. Avoid danger by keeping is injected into the skin, obtain medical
sparks, open flames and smoking materials attention immediately or gangrene may result.
away from vehicle and fuel during refueling or D. Battery
fuel system servicing. Know where fire extin-
guishers are kept on the worksite and how to The following WARNING is intended to supple-
use them. ment and does not replace the warnings and
information provided on the battery by the
C. Hydraulic Fluid battery manufacturer.
• DO NOT attempt to repair or tighten any
hydraulic hoses or fittings while the engine is
running or when the hydraulic system is under
pressure. Fluid in the hydraulic system is
under enough pressure that it can penetrate
the skin causing serious injury or death.
• HOT HYDRAULIC FLUID WILL CAUSE
SEVERE BURNS. Wait for fluid to cool down
before disconnecting lines.
OG0360

8042 Rev 3/04 Page 5

 When jump starting the vehicle, carefully follow 5. Moving Parts Hazard
instructions found under "Jump Starting" later in
this manual. DO NOT place limbs near
moving parts. Amputation of
Keep sparks, flames, and lit cigarettes away any body part can result.
from battery at all times. Lead acid batteries Turn off engine and wait until
generate explosive gases. Severe chemical fan and belts stop moving
burns can result from improper handling of before servicing the vehicle.
battery electrolyte. Wear safety glasses and
proper protective gear when handling batteries
to prevent electrolyte from coming in contact
with eyes, skin or clothing.

Battery Electrolyte First Aid OG0330

• External Contact — Flush with water.

• Eyes — Flush with water for at least 15 6. Lowering Boom or Falling Load Hazard
minutes and get medical attention DO NOT get under a raised boom unless the boom is
immediately! blocked up safely. Always empty the boom of any load
• Internal Contact — Drink large quantities of and block up the boom before doing any servicing
water. Follow with Milk of Magnesia, beaten which requires the boom to be raised.
egg or vegetable oil. Get medical attention NEVER allow anyone to walk or stand under a raised
immediately! boom. A lowering boom or falling load can result in
serious injury or death.
IMPORTANT: In case of internal contact, DO
NOT give fluids that would induce vomiting!

Page 6 8042 Rev 3/04

When jump starting the vehicle, carefully follow 5. Moving Parts Hazard
instructions found under "Jump Starting" later in
this manual. DO NOT place limbs near
moving parts. Amputation of
Keep sparks, flames, and lit cigarettes away any body part can result.
from battery at all times. Lead acid batteries Turn off engine and wait until
generate explosive gases. Severe chemical fan and belts stop moving
burns can result from improper handling of before servicing the vehicle.
battery electrolyte. Wear safety glasses and
proper protective gear when handling batteries
to prevent electrolyte from coming in contact
with eyes, skin or clothing.

Battery Electrolyte First Aid OG0330

• External Contact — Flush with water.

• Eyes — Flush with water for at least 15 6. Lowering Boom or Falling Load Hazard
minutes and get medical attention DO NOT get under a raised boom unless the boom is
immediately! blocked up safely. Always empty the boom of any load
• Internal Contact — Drink large quantities of and block up the boom before doing any servicing
water. Follow with Milk of Magnesia, beaten which requires the boom to be raised.
egg or vegetable oil. Get medical attention NEVER allow anyone to walk or stand under a raised
immediately! boom. A lowering boom or falling load can result in
serious injury or death.
IMPORTANT: In case of internal contact, DO
NOT give fluids that would induce vomiting!

Page 6 8042 Rev 3/04

 Operational Considerations Prevent accidents when you move the vehicle
around the worksite. Know the rules for movement
1. Preparation and Prevention of people and vehicles on the worksite. Follow the
instructions 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 driving
under electrical lines, bridges, etc.
OG0380
3. Underground Hazards
Know the location and function of all vehicle controls.
Know the location of all underground hazards
Make sure all persons are away from the vehicle and
before operating the vehicle in a new work area.
that the Travel and Gear Select Lever is locked in the
Electrical cables, gas pipes, water pipes, sewers, or
(N) NEUTRAL position with the emergency brake
other underground objects can cause injury or
switch engaged before starting the engine.
death. Contact your local underground utility
Holes, obstructions, debris and other work area service or diggers' hotline to mark all underground
hazards can cause injury or death. Always walk hazards.
around and look for these and other hazards before
operating the vehicle in a new work area.

8042 Rev 3/04 Page 7

Operational Considerations Prevent accidents when you move the vehicle

around the worksite. Know the rules for movement
1. Preparation and Prevention of people and vehicles on the worksite. Follow the
instructions 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 driving
under electrical lines, bridges, etc.
OG0380
3. Underground Hazards
Know the location and function of all vehicle controls.
Know the location of all underground hazards
Make sure all persons are away from the vehicle and
before operating the vehicle in a new work area.
that the Travel and Gear Select Lever is locked in the
Electrical cables, gas pipes, water pipes, sewers, or
(N) NEUTRAL position with the emergency brake
other underground objects can cause injury or
switch engaged before starting the engine.
death. Contact your local underground utility
Holes, obstructions, debris and other work area service or diggers' hotline to mark all underground
hazards can cause injury or death. Always walk hazards.
around and look for these and other hazards before
operating the vehicle in a new work area.

8042 Rev 3/04 Page 7

4. Electrocution Hazard 5. Lifting Personnel

OG0351
NEVER operate this vehicle in an area in which
overhead power lines, overhead or underground
cables, or power sources exist without first request-
ing that the appropriate power company or utility
company de-energize the lines or take other suitable
precautions.
OG0341

Use only an approved work platform for lifting and

lowering personnel. NEVER transport personnel in
a work platform for even the shortest distance.
Serious injury or death can occur if these rules are
not obeyed. Riders can fall and be crushed or run
over. Avoid accidents. For other specific precau-
tions, see “Elevating Personnel” later in this manual.

Page 8 8042 Rev 3/04

4. Electrocution Hazard 5. Lifting Personnel

OG0351
NEVER operate this vehicle in an area in which
overhead power lines, overhead or underground
cables, or power sources exist without first request-
ing that the appropriate power company or utility
company de-energize the lines or take other suitable
precautions.
OG0341

Use only an approved work platform for lifting and

lowering personnel. NEVER transport personnel in
a work platform for even the shortest distance.
Serious injury or death can occur if these rules are
not obeyed. Riders can fall and be crushed or run
over. Avoid accidents. For other specific precau-
tions, see “Elevating Personnel” later in this manual.

Page 8 8042 Rev 3/04

6. Tip Over Hazard
ALWAYS make sure that all four tires have been
properly filled with hydrofill by a qualified tire service
center.
DO NOT exceed the Traveling with the boom raised is dangerous and can
rated lift capacity of the cause tipover. Keep the load as low as possible.
vehicle, as structural Travel with extreme caution and at the slowest
damage and unstable possible speed.
vehicle conditions will Driving across a slope is dangerous, as unexpected
result. changes in the slope can cause tipover. Ascend or
descend slopes slowly and with caution.
Keep the vehicle under control at all times.
OG0371 Avoid jerky turns, starts, or stops. Reduce operating
speed on rough ground and slopes.
If proper operating procedures are not followed,
this vehicle will tip over. If a vehicle ever becomes Frame tilting with the boom raised above horizontal is
unstable and starts to tip over, dangerous. Always use the frame tilt to level the
vehicle before raising the boom above horizontal, with
• BRACE YOURSELF and STAY WITH THE or without a load. If the vehicle cannot be leveled
VEHICLE. using the frame tilt, reposition the vehicle.
• KEEP SEAT BELT FASTENED,
• HOLD ON FIRMLY and
• LEAN AWAY FROM THE POINT OF IMPACT.
Indecision and trying to escape from a tipping vehicle
can result in death or injury.

8042 Rev 3/04 Page 9

6. Tip Over Hazard

ALWAYS make sure that all four tires have been
properly filled with hydrofill by a qualified tire service
center.
DO NOT exceed the Traveling with the boom raised is dangerous and can
rated lift capacity of the cause tipover. Keep the load as low as possible.
vehicle, as structural Travel with extreme caution and at the slowest
damage and unstable possible speed.
vehicle conditions will Driving across a slope is dangerous, as unexpected
result. changes in the slope can cause tipover. Ascend or
descend slopes slowly and with caution.
Keep the vehicle under control at all times.
OG0371 Avoid jerky turns, starts, or stops. Reduce operating
speed on rough ground and slopes.
If proper operating procedures are not followed,
this vehicle will tip over. If a vehicle ever becomes Frame tilting with the boom raised above horizontal is
unstable and starts to tip over, dangerous. Always use the frame tilt to level the
vehicle before raising the boom above horizontal, with
• BRACE YOURSELF and STAY WITH THE or without a load. If the vehicle cannot be leveled
VEHICLE. using the frame tilt, reposition the vehicle.
• KEEP SEAT BELT FASTENED,
• HOLD ON FIRMLY and
• LEAN AWAY FROM THE POINT OF IMPACT.
Indecision and trying to escape from a tipping vehicle
can result in death or injury.

8042 Rev 3/04 Page 9

 7. Slopes
DO NOT park the vehicle on an incline and leave it
unattended.
• Driving across a slope is dangerous, as
unexpected changes in the slope can cause
tipover. Ascend or descend slopes slowly and
with caution.
• Ascend or descend slopes with the heavy end of
the vehicle pointing up the slope.
NOTE: The rear of the vehicle is normally consid-
ered the heavy end unless the carriage is fully
loaded. In this case the front of the vehicle is now
the heavy end.
• Unloaded vehicles should be operated on all
OH0331 slopes with the carriage pointing down the slope.
• On all slopes, the load must be tilted back and
DO NOT remove or unpin the rear stabilizer cylinder raised only as far as necessary to clear the
from the vehicle, as unstable vehicle conditions will ground.
result. • When operating on a downhill slope, reduce travel
ALWAYS be sure the Stabil-TRAK system is speed and downshift to a low gear to permit
functioning properly when operating the vehicle. compression braking by the engine and aid the
Refer to “Stabil-TRAK System Test” later in this application of the service brakes.
manual for proper system function.

Page 10 8042 Rev 3/04

7. Slopes
DO NOT park the vehicle on an incline and leave it
unattended.
• Driving across a slope is dangerous, as
unexpected changes in the slope can cause
tipover. Ascend or descend slopes slowly and
with caution.
• Ascend or descend slopes with the heavy end of
the vehicle pointing up the slope.
NOTE: The rear of the vehicle is normally consid-
ered the heavy end unless the carriage is fully
loaded. In this case the front of the vehicle is now
the heavy end.
• Unloaded vehicles should be operated on all
OH0331 slopes with the carriage pointing down the slope.
• On all slopes, the load must be tilted back and
DO NOT remove or unpin the rear stabilizer cylinder raised only as far as necessary to clear the
from the vehicle, as unstable vehicle conditions will ground.
result. • When operating on a downhill slope, reduce travel
ALWAYS be sure the Stabil-TRAK system is speed and downshift to a low gear to permit
functioning properly when operating the vehicle. compression braking by the engine and aid the
Refer to “Stabil-TRAK System Test” later in this application of the service brakes.
manual for proper system function.

Page 10 8042 Rev 3/04

8. Falling Load Hazard Equipment Considerations
DO NOT exceed the total rated load capacity of the
specific type fork being used. Each fork is stamped
ALWAYS make sure that all four tires have been
with a maximum load capacity. If capacity is
properly filled with hydrofill by a qualified tire service
exceeded, forks may break. See “Fork Ratings”
center. Improper hydrofill can cause instability
later in this manual.
which can result in tipover.
DO NOT downshift at a high ground speed. You
may drop the load off of the forks due to a sudden
slowing.
WARNING
9. Visual Obstruction DO NOT modify or alter (weld, drill, etc.) any part of
Dust, smoke, fog, etc. can decrease vision and this vehicle without consulting JLG. Modifications
cause an accident. Always stop or slow the vehicle can weaken the structure creating a hazard that can
until the obstruction clears and the work area is cause injury or death.
visible again.
10. Ventilation
Sparks from the electrical system and engine
exhaust can cause an explosion. DO NOT operate
this vehicle in an area with flammable dust or
vapors, unless good ventilation has removed the
hazard.
Carbon monoxide fumes from the engine exhaust
can also cause suffocation in an enclosed area.
Good ventilation is very important when operating
this vehicle.

8042 Rev 3/04 Page 11

8. Falling Load Hazard Equipment Considerations

DO NOT exceed the total rated load capacity of the
specific type fork being used. Each fork is stamped
ALWAYS make sure that all four tires have been
with a maximum load capacity. If capacity is
properly filled with hydrofill by a qualified tire service
exceeded, forks may break. See “Fork Ratings”
center. Improper hydrofill can cause instability
later in this manual.
which can result in tipover.
DO NOT downshift at a high ground speed. You
may drop the load off of the forks due to a sudden

9.
slowing.

Visual Obstruction
WARNING
DO NOT modify or alter (weld, drill, etc.) any part of
Dust, smoke, fog, etc. can decrease vision and this vehicle without consulting JLG. Modifications
cause an accident. Always stop or slow the vehicle can weaken the structure creating a hazard that can
until the obstruction clears and the work area is cause injury or death.
visible again.
10. Ventilation
Sparks from the electrical system and engine
exhaust can cause an explosion. DO NOT operate
this vehicle in an area with flammable dust or
vapors, unless good ventilation has removed the
hazard.
Carbon monoxide fumes from the engine exhaust
can also cause suffocation in an enclosed area.
Good ventilation is very important when operating
this vehicle.

8042 Rev 3/04 Page 11

Operation
STEERING WHEEL
Controls
Ignition Switch (See Figure 1)
Using the ignition switch key, the switch may be turned
clockwise from the OFF position to the RUN and START
positions. The START position is spring-loaded to
return to the RUN position and must be manually held in
IGNITION SWITCH
place for normal starting.
OFF position — The entire electrical system is shut down.
RUN position — All controls and indicators are operable.
SERVICE BRAKE PEDAL
START position — Engages starter to crank the engine
when the emergency brake switch is engaged and the
ACCELERATOR PEDAL
transmission is in neutral.
OH1150
Figure 1
Accelerator Pedal (See Figure 1)
Pressing down the accelerator pedal increases travel boom angles are greater than 40°, as long as the pedal
speed of the vehicle. The pedal is spring-loaded to is depressed.
return to idle speed.
Steering Wheel (See Figure 1)
Service Brake Pedal (See Figure 1) Turning the steering wheel to the left or right steers the
Pressing down the brake pedal applies the wet disc vehicle in the corresponding direction. Any one of three
service brakes located in the axle wheel ends. It also steering modes are selectable. Refer to “Steering
activates and locks the rear axle lock system when Select Switch.”

Page 12 8042 Rev 3/04

Operation
STEERING WHEEL
Controls
Ignition Switch (See Figure 1)
Using the ignition switch key, the switch may be turned
clockwise from the OFF position to the RUN and START
positions. The START position is spring-loaded to
return to the RUN position and must be manually held in
IGNITION SWITCH
place for normal starting.
OFF position — The entire electrical system is shut down.
RUN position — All controls and indicators are operable.
SERVICE BRAKE PEDAL
START position — Engages starter to crank the engine
when the emergency brake switch is engaged and the
ACCELERATOR PEDAL
transmission is in neutral.
OH1150
Figure 1
Accelerator Pedal (See Figure 1)
Pressing down the accelerator pedal increases travel boom angles are greater than 40°, as long as the pedal
speed of the vehicle. The pedal is spring-loaded to is depressed.
return to idle speed.
Steering Wheel (See Figure 1)
Service Brake Pedal (See Figure 1) Turning the steering wheel to the left or right steers the
Pressing down the brake pedal applies the wet disc vehicle in the corresponding direction. Any one of three
service brakes located in the axle wheel ends. It also steering modes are selectable. Refer to “Steering
activates and locks the rear axle lock system when Select Switch.”

Page 12 8042 Rev 3/04

 EMERGENCY
STEERING Steering Select Switch (See Figure 2)
SELECT SWITCH
BRAKE This switch has three positions:
SWITCH
Four Wheel Steer ...... up position

EMERGENCY

DANGER
BRAKE

Two Wheel Steer ...... center position

WARNING SAFETY INSTRUCTIONS
P
1. Read operator's manual before
Loader
Before Exiting
Lower Boom Manual Riderss
Read Operators
Belt
No
Fasten Seat

operating.

2. Fasten seat belt.

3. Allow no riders.

4. Use
se an approved work platform MACHINE TIPOVER can result
MACHINE ROLL AWAY to lift or lower personnel. in death or serious injury.
can cause death or • Level machine before raising boom.
ous injury.
serious injury • Lower raised boom before traveling.
• Operate only with hydrofill in all 4 tires.
ALWAYS engage
parking brake before
P • Consult capacity chart for load limits. DANGER
dismounting. CONTACT WITH ELECTRIC
POWER LINES can result in
electrocution.
Never operate this machine within
10 feet of electric power lines.
Notify the power company to
de-energize the lines before

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

operating forklift.

OH0780

Refer to Steering under "Operating" for detailed information.

Emergency Brake Switch (See Figure 2)
TRAVEL
AND The emergency brake switch has two positions:
GEAR Engaged ............... lift red switch cover then
SELECT P
LEVER push switch up
P Disengaged .......... lower red switch cover
NEUTRAL
LOCK OG0390 then push switch down
LEVER
The emergency brake must be ENGAGED to permit
ND
HORN engine starting. Operator should use caution when
BUTTON engaging the emergency brake while vehicle is moving,
because the stop will be abrupt and operator may be
Figure 2 OH1160 jolted forward unexpectedly. The emergency brake may
be used to stop in an emergency situation. The emer-
gency brake switch will also activate the Stabil-TRAK
system when boom angles are greater than 40°. The
vehicle will then enter “LOCKED MODE.”

8042 Rev 3/04 Page 13

EMERGENCY
STEERING Steering Select Switch (See Figure 2)
SELECT SWITCH
BRAKE This switch has three positions:
SWITCH
Four Wheel Steer ...... up position

EMERGENCY

DANGER
BRAKE

Two Wheel Steer ...... center position

WARNING SAFETY INSTRUCTIONS
P
1. Read operator's manual before
Loader
Before Exiting
Lower Boom Manual Riderss
Read Operators
Belt
No
Fasten Seat

operating.

2. Fasten seat belt.

3. Allow no riders.

4. Use
se an approved work platform MACHINE TIPOVER can result
MACHINE ROLL AWAY to lift or lower personnel. in death or serious injury.
can cause death or • Level machine before raising boom.
serious
ous injury.
injury • Lower raised boom before traveling.
• Operate only with hydrofill in all 4 tires.
ALWAYS engage
parking brake before
P • Consult capacity chart for load limits. DANGER
dismounting. CONTACT WITH ELECTRIC
POWER LINES can result in
electrocution.
Never operate this machine within
10 feet of electric power lines.
Notify the power company to
de-energize the lines before

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

operating forklift.

OH0780

Refer to Steering under "Operating" for detailed information.

Emergency Brake Switch (See Figure 2)
TRAVEL
AND The emergency brake switch has two positions:
GEAR Engaged ............... lift red switch cover then
SELECT P
LEVER push switch up
P Disengaged .......... lower red switch cover
NEUTRAL
LOCK OG0390 then push switch down
LEVER
The emergency brake must be ENGAGED to permit
ND
HORN engine starting. Operator should use caution when
BUTTON engaging the emergency brake while vehicle is moving,
because the stop will be abrupt and operator may be
Figure 2 OH1160 jolted forward unexpectedly. The emergency brake may
be used to stop in an emergency situation. The emer-
gency brake switch will also activate the Stabil-TRAK
system when boom angles are greater than 40°. The
vehicle will then enter “LOCKED MODE.”

8042 Rev 3/04 Page 13

Travel Select Lever (See Figure 2)
The travel select lever has three positions to select
direction 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 automatically
sound.
NOTE: The travel select lever must be in NEUTRAL to
permit engine starting and when boom angles are greater
than 40°, shifting into NEUTRAL locks the Stabil-TRAK GEAR SELECT
LEVER
system.
Gear Select Lever (See Figure 3) Figure 3 OH1270
The gear select lever has a four position twist grip
handle. The vehicle’s transmission has three (3) forward Neutral Lock Lever (See Figure 2)
gears and three (3) reverse gears. To change gears, The travel select lever is equipped with a neutral lock.
rotate the twist grip to the next desired gear. Use first
gear for highest torque and pulling power. Use higher To lock the travel select lever in the NEUTRAL position:
gears for higher ground speed. Selecting the fourth Place the lever in the NEUTRAL position and move
position on the gear select lever will have no effect on the neutral lock lever to the (N) NEUTRAL LOCK
the three speed transmission. position.
To unlock, move the neutral lock lever to the (D) DRIVE
position.

Page 14 8042 Rev 3/04

Travel Select Lever (See Figure 2)

The travel select lever has three positions to select
direction 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 automatically
sound.
NOTE: The travel select lever must be in NEUTRAL to
permit engine starting and when boom angles are greater
than 40°, shifting into NEUTRAL locks the Stabil-TRAK GEAR SELECT
LEVER
system.
Gear Select Lever (See Figure 3) Figure 3 OH1270
The gear select lever has a four position twist grip
handle. The vehicle’s transmission has three (3) forward Neutral Lock Lever (See Figure 2)
gears and three (3) reverse gears. To change gears, The travel select lever is equipped with a neutral lock.
rotate the twist grip to the next desired gear. Use first
gear for highest torque and pulling power. Use higher To lock the travel select lever in the NEUTRAL position:
gears for higher ground speed. Selecting the fourth Place the lever in the NEUTRAL position and move
position on the gear select lever will have no effect on the neutral lock lever to the (N) NEUTRAL LOCK
the three speed transmission. position.
To unlock, move the neutral lock lever to the (D) DRIVE
position.

Page 14 8042 Rev 3/04

Horn Button (See Figure 2) The speed of boom movement depends on the amount
of lever movement in the corresponding direction. The
Pressing the momentary-contact horn button sounds
overall speed of movement depends directly upon the
the vehicle horn.
speed of the engine.
Boom Control Lever (See Figure 4)
The boom control lever is a joystick with variable
motion from the center to control the boom functions:

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

Boom Lower ....... move lever forward BOOM CONTROL

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

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

FRAME TILT
OH0170 CONTROL
LEVER
Two boom functions can be accomplished at the same
time by moving the lever into the proper quadrant. For Figure 4 0H0360

example: moving the lever forward and to the left will

lower and retract the boom simultaneously.

8042 Rev 3/04 Page 15

Horn Button (See Figure 2) The speed of boom movement depends on the amount
of lever movement in the corresponding direction. The
Pressing the momentary-contact horn button sounds
overall speed of movement depends directly upon the
the vehicle horn.
speed of the engine.
Boom Control Lever (See Figure 4)
The boom control lever is a joystick with variable
motion from the center to control the boom functions:

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

Boom Lower ....... move lever forward BOOM CONTROL

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

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

FRAME TILT
OH0170 CONTROL
LEVER
Two boom functions can be accomplished at the same
time by moving the lever into the proper quadrant. For Figure 4 0H0360

example: moving the lever forward and to the left will

lower and retract the boom simultaneously.

8042 Rev 3/04 Page 15

Attachment and Frame Tilt Control Lever Circulation Fan (Enclosed Cab Only)
(See Figure 4) (Not Pictured)
The attachment and frame tilt control is a joystick with The circulation fan is only operable when the ignition
four perpendicular motions from the center to control switch is in the RUN position. The fan switch is located
two attachment functions and two frame tilt functions: at the base of the fan mount.

Frame Tilt Left ............... move lever to the left Sliding Windows (Enclosed Cab Only)
(Not Pictured)
Frame Tilt Right ............ move lever to the right The sliding windows are latched with a combination slide
bar and squeeze actuated latch.

Attachment Tilt Down .... move lever forward

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

OH0410

The attachment is self leveling and will retain any set

angle throughout boom raising, lowering, retracting or
extending operations.

Page 16 8042 Rev 3/04

Attachment and Frame Tilt Control Lever Circulation Fan (Enclosed Cab Only)
(See Figure 4) (Not Pictured)
The attachment and frame tilt control is a joystick with The circulation fan is only operable when the ignition
four perpendicular motions from the center to control switch is in the RUN position. The fan switch is located
two attachment functions and two frame tilt functions: at the base of the fan mount.

Frame Tilt Left ............... move lever to the left Sliding Windows (Enclosed Cab Only)
(Not Pictured)
Frame Tilt Right ............ move lever to the right The sliding windows are latched with a combination slide
bar and squeeze actuated latch.

Attachment Tilt Down .... move lever forward

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

OH0410

The attachment is self leveling and will retain any set

angle throughout boom raising, lowering, retracting or
extending operations.

Page 16 8042 Rev 3/04

Rear Window Control (Enclosed Cab Only) PIVOT ARM KNOB
(See Figure 5)
Loosen the knob and slide the pivot arm in the slot to
open the rear window. Tighten the knob to secure.
Reverse the procedure to close the window.
NOTE: The rear window can be used as an emergency
exit if necessary. Unscrew the knob from the stud, raise
the pivot arm over the stud, and push the window out.
OA0052
Figure 5
Door Latches (Enclosed Cab Only)
(Not Pictured)
There are two door latches. The outside latch is a key
Roof Washer/Wiper Control
lockable pull to release type. The inside latch is a push (Enclosed Cab Only) (Not Pictured)
to release type. Turn the knob clockwise to operate the wiper. Pressing
the knob activates the roof washer for as long as it is
held in. The washer fluid tank is the rear tank located
Windshield Washer/Wiper Control next to the seat support.
(Enclosed Cab Only) (Not Pictured)
Turn the knob counterclockwise to operate the wipers
at low speed; turn the knob clockwise to operate the
wipers at high speed. Pressing the knob activates the
windshield washer for as long as it is held in. The
windshield washer fluid tank is located to the rear of the
right console (early models) or it is the front tank next to
the seat support (later models).

8042 Rev 3/04 Page 17

Rear Window Control (Enclosed Cab Only) PIVOT ARM KNOB

(See Figure 5)
Loosen the knob and slide the pivot arm in the slot to
open the rear window. Tighten the knob to secure.
Reverse the procedure to close the window.
NOTE: The rear window can be used as an emergency
exit if necessary. Unscrew the knob from the stud, raise
the pivot arm over the stud, and push the window out.
OA0052
Figure 5
Door Latches (Enclosed Cab Only)
(Not Pictured)
There are two door latches. The outside latch is a key
Roof Washer/Wiper Control
lockable pull to release type. The inside latch is a push (Enclosed Cab Only) (Not Pictured)
to release type. Turn the knob clockwise to operate the wiper. Pressing
the knob activates the roof washer for as long as it is
held in. The washer fluid tank is the rear tank located
Windshield Washer/Wiper Control next to the seat support.
(Enclosed Cab Only) (Not Pictured)
Turn the knob counterclockwise to operate the wipers
at low speed; turn the knob clockwise to operate the
wipers at high speed. Pressing the knob activates the
windshield washer for as long as it is held in. The
windshield washer fluid tank is located to the rear of the
right console (early models) or it is the front tank next to
the seat support (later models).

8042 Rev 3/04 Page 17

Cab Heater (Enclosed Cab Only) Height — Height adjustment is achieved by grasping the
(See Figure 6) bottom of the seat and raising upward into one of the
three detent positions. Once the seat has reached the
The cab heater fan is only operable when the ignition
highest detent position, it can be lowered by raising the
switch is in the RUN position. The heater fan switch is
seat all the way and lowering it fully. The seat can then
located on the left side of the seat base (Figure 6). The
be raised, one detent at a time to the desired height.
switch has three positions: OFF, LO, and HI.
Forward/Backward — Release the lever on the left side
NOTE: During warm weather operation, close the heater of the seat and slide seat forward or backward to suit.
line shut-off valve, located in the heater hose connection
at the engine. (Valve is located below engine alternator.)
Seat Belt (See Figure 6)
The seat belt has a slide on each strap that is used to
tighten and loosen the strap on each side of the buckle.
To shorten, pull bottom of loop toward buckle. To
lengthen, hold slide strap, pull slide toward buckle and SEAT
readjust buckle on loop. Buckle the two straps together BELT
to fasten. Lift the buckle latch or press the center button
to unfasten the seat belt.
SUSPENSION
Always wear the seat belt when operating the vehicle. ADJUST KNOB
An optional 3 inch wide seat belt is available for those FORWARD/
BACKWARD
location that require a 3 inch seat belt. LEVER
Operator's Seat Adjustment (See Figure 6)
The position and suspension of the operator's seat can HEATER
be adjusted. CAB HEATER CONTROL

Suspension — Turn the knob on the front of the seat to Figure 6 OA0071
adjust suspension stiffness for operator weight.

Page 18 8042 Rev 3/04

Cab Heater (Enclosed Cab Only) Height — Height adjustment is achieved by grasping the
(See Figure 6) bottom of the seat and raising upward into one of the
three detent positions. Once the seat has reached the
The cab heater fan is only operable when the ignition
highest detent position, it can be lowered by raising the
switch is in the RUN position. The heater fan switch is
seat all the way and lowering it fully. The seat can then
located on the left side of the seat base (Figure 6). The
be raised, one detent at a time to the desired height.
switch has three positions: OFF, LO, and HI.
Forward/Backward — Release the lever on the left side
NOTE: During warm weather operation, close the heater of the seat and slide seat forward or backward to suit.
line shut-off valve, located in the heater hose connection
at the engine. (Valve is located below engine alternator.)
Seat Belt (See Figure 6)
The seat belt has a slide on each strap that is used to
tighten and loosen the strap on each side of the buckle.
To shorten, pull bottom of loop toward buckle. To
lengthen, hold slide strap, pull slide toward buckle and SEAT
readjust buckle on loop. Buckle the two straps together BELT
to fasten. Lift the buckle latch or press the center button
to unfasten the seat belt.
SUSPENSION
Always wear the seat belt when operating the vehicle. ADJUST KNOB
An optional 3 inch wide seat belt is available for those FORWARD/
BACKWARD
location that require a 3 inch seat belt. LEVER
Operator's Seat Adjustment (See Figure 6)
The position and suspension of the operator's seat can HEATER
be adjusted. CAB HEATER CONTROL

Suspension — Turn the knob on the front of the seat to Figure 6 OA0071
adjust suspension stiffness for operator weight.

Page 18 8042 Rev 3/04

 Instruments and Indicators
Stabil-TRAK™ Light
DANGER
(See Figure 7) Vehicle tipover can result in death or serious
OH0350 injury.
The Stabil-TRAK light will come ON when the system Traveling with the boom raised is dangerous and
has been activated. The rear axle will lock when one or can cause vehicle tipover. Keep the load as low
more of the following conditions exist with the boom as possible. Travel with extreme caution and at
above a 40° angle. the slowest possible speed.
• Emergency brake switch engaged

• Travel and gear select lever in (N) NEUTRAL

• Service brake pedal depressed

With the boom above a 40° angle and traveling in a

forward or reverse drive gear, the Stabil-TRAK Light will
go OFF. In this condition the rear axle is unlocked and
is allowed to pivot, but will respond slowly to changes in
terrain.

ALWAYS be sure the Stabil-TRAK system is function-

ing properly when operating vehicle. Refer to “Under-
standing the Stabil-TRAK System” later in this manual STABIL-TRAK
LIGHT
for a detailed explanation of this system.

Figure 7 OH1220

8042 Rev 3/04 Page 19

Instruments and Indicators

Stabil-TRAK™ Light
DANGER
(See Figure 7) Vehicle tipover can result in death or serious
OH0350 injury.
The Stabil-TRAK light will come ON when the system Traveling with the boom raised is dangerous and
has been activated. The rear axle will lock when one or can cause vehicle tipover. Keep the load as low
more of the following conditions exist with the boom as possible. Travel with extreme caution and at
above a 40° angle. the slowest possible speed.
• Emergency brake switch engaged

• Travel and gear select lever in (N) NEUTRAL

• Service brake pedal depressed

With the boom above a 40° angle and traveling in a

forward or reverse drive gear, the Stabil-TRAK Light will
go OFF. In this condition the rear axle is unlocked and
is allowed to pivot, but will respond slowly to changes in
terrain.

ALWAYS be sure the Stabil-TRAK system is function-

ing properly when operating vehicle. Refer to “Under-
standing the Stabil-TRAK System” later in this manual STABIL-TRAK
LIGHT
for a detailed explanation of this system.

Figure 7 OH1220

8042 Rev 3/04 Page 19

Warning Lights (See Figure 7A) • Engine Water Temperature Light
There are four warning lights in a cluster between the Indicates high engine coolant temperature.
hourmeter and fuel gauge. When the ignition switch is • Engine Oil Pressure Light
turned to the RUN position the Engine Oil Pressure and Indicates low engine oil pressure.
Alternator Charge indicators will light up. This is a normal • Alternator Charging Light
condition. While the engine is running, all lights should be Indicates alternator is not charging.
OFF. However, if any of the lights turn ON an abnormal • Transmission/Hydraulic Oil Temperature Light
condition exists. These conditions are: Indicates high transmission or hydraulic oil
temperature.
WARNING FUEL WARNING LIGHT
HOURMETER LIGHTS GAUGE BULB TEST ENGINE WATER ALTERNATOR
BUTTON TEMPERATURE CHARGING
LIGHT LIGHT

TRANSMISSION/
ENGINE OIL HYDRAULIC OIL
PRESSURE TEMPERATURE
LIGHT OH0371 LIGHT

Figure 7A OH1220

Page 20 8042 Rev 3/04

Warning Lights (See Figure 7A) • Engine Water Temperature Light

There are four warning lights in a cluster between the Indicates high engine coolant temperature.
hourmeter and fuel gauge. When the ignition switch is • Engine Oil Pressure Light
turned to the RUN position the Engine Oil Pressure and Indicates low engine oil pressure.
Alternator Charge indicators will light up. This is a normal • Alternator Charging Light
condition. While the engine is running, all lights should be Indicates alternator is not charging.
OFF. However, if any of the lights turn ON an abnormal • Transmission/Hydraulic Oil Temperature Light
condition exists. These conditions are: Indicates high transmission or hydraulic oil
temperature.
WARNING FUEL WARNING LIGHT
HOURMETER LIGHTS GAUGE BULB TEST ENGINE WATER ALTERNATOR
BUTTON TEMPERATURE CHARGING
LIGHT LIGHT

TRANSMISSION/
ENGINE OIL HYDRAULIC OIL
PRESSURE TEMPERATURE
LIGHT OH0371 LIGHT

Figure 7A OH1220

Page 20 8042 Rev 3/04

Warning Light Bulb Test Button (See Figure 7A)
Directly to the right of the instrument cluster is a warning
light bulb test button. With ignition switch in the RUN
position and engine OFF, depress this button to test all
warning lights. If any of the lights are burnt out, replace
the bulb(s) immediately.

Fuel Gauge (See Figure 7A)

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

Hourmeter (See Figure 7A)

Indicates the total elapsed hours of operation.

Rear View Mirrors (Not Pictured)

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

8042 Rev 3/04 Page 21

Warning Light Bulb Test Button (See Figure 7A)

Directly to the right of the instrument cluster is a warning
light bulb test button. With ignition switch in the RUN
position and engine OFF, depress this button to test all
warning lights. If any of the lights are burnt out, replace
the bulb(s) immediately.

Fuel Gauge (See Figure 7A)

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

Hourmeter (See Figure 7A)

Indicates the total elapsed hours of operation.

Rear View Mirrors (Not Pictured)

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

8042 Rev 3/04 Page 21

Frame Level Indicator (See Figure 8)
The indicator is mounted on the top inside of the Opera-
4105262

tor's Protective Structure (cab). This is a bubble type

indicator which allows the operator to tell if the vehicle
has been positioned in a level condition. Always frame
tilt the vehicle either right or left until the indicator reads PLUMB
zero degrees (0°). If zero cannot be achieved, then ARROW
reposition the vehicle until it is level before placing the
load.
NOTE: Maximum frame tilt is 10° in either direction.

SCALE

0°
Figure 9 OH0301

Boom Angle Indicator (See Figure 9)

The boom angle indicator is a plumb arrow with angular
graduations from minus 10° to plus 80°. It is located on
FRAME LEVEL
INDICATOR the left side of the boom and is visible from the
operator’s position. Use this indicator to determine the
OA0092 boom angle when reading the capacity chart (see “Using
Figure 8
The Capacity Chart”).

Page 22 8042 Rev 3/04

Frame Level Indicator (See Figure 8)

The indicator is mounted on the top inside of the Opera-
4105262

tor's Protective Structure (cab). This is a bubble type

indicator which allows the operator to tell if the vehicle
has been positioned in a level condition. Always frame
tilt the vehicle either right or left until the indicator reads PLUMB
zero degrees (0°). If zero cannot be achieved, then ARROW
reposition the vehicle until it is level before placing the
load.
NOTE: Maximum frame tilt is 10° in either direction.

SCALE

0°
Figure 9 OH0301

Boom Angle Indicator (See Figure 9)

The boom angle indicator is a plumb arrow with angular
graduations from minus 10° to plus 80°. It is located on
FRAME LEVEL
INDICATOR the left side of the boom and is visible from the
operator’s position. Use this indicator to determine the
OA0092 boom angle when reading the capacity chart (see “Using
Figure 8
The Capacity Chart”).

Page 22 8042 Rev 3/04

 Optional Controls DIRECTIONAL SIGNAL
Light Switch (See Figure 10) LEVER

A three-position push-pull switch controls the lights of

the optional light package. EMERGENCY FLASHER
SLIDE CONTROL
• Switch In = Lights OFF.

• Switch Halfway Out = Headlights and Taillights.

• Switch Fully Out = Headlights, Taillights, Rear Work

Lights and Boom Work Light.

LIGHT HORN
SWITCH BUTTON
Figure 11 OA0623

Directional Signals (See Figure 11)

Push the lever to the left and down to signal a left turn;
to the right and up for a right turn. The signals are NOT
self-canceling; the lever must be moved to the center
OFF position after the indicated turn is negotiated.
To operate the emergency flashers, push or lift up the
slide control. To cancel the flashers, engage the
Figure 10 OA0612
directional lever momentarily.

8042 Rev 3/04 Page 23

Optional Controls DIRECTIONAL SIGNAL

Light Switch (See Figure 10) LEVER

A three-position push-pull switch controls the lights of

the optional light package. EMERGENCY FLASHER
SLIDE CONTROL
• Switch In = Lights OFF.

• Switch Halfway Out = Headlights and Taillights.

• Switch Fully Out = Headlights, Taillights, Rear Work

Lights and Boom Work Light.

LIGHT HORN
SWITCH BUTTON
Figure 11 OA0623

Directional Signals (See Figure 11)

Push the lever to the left and down to signal a left turn;
to the right and up for a right turn. The signals are NOT
self-canceling; the lever must be moved to the center
OFF position after the indicated turn is negotiated.
To operate the emergency flashers, push or lift up the
slide control. To cancel the flashers, engage the
Figure 10 OA0612
directional lever momentarily.

8042 Rev 3/04 Page 23

 When the control lever is moved to the left it will
provide hydraulic system pressure to the male
disconnect coupling for the auxiliary attach-
OH0451 ment. Hydraulic fluid will return to the tank
AUXILIARY ATTACHMENT through the female disconnect coupling.
CONTROL LEVER
The control lever will provide the following typical func-
tions for each specific attachment if they are connected
properly. Operation will be reversed if incorrectly con-
nected. We recommend reversing the disconnect
couplings on the hoses that are supplied with the attach-
Figure 12 OH0381 ment if operation is reversed.
Side Tilt Carriage Operation:
Auxiliary Attachment Control Lever • Lever right ....... tilt right
(See Figure 12) • Lever left ......... tilt left
The auxiliary attachment control lever controls the
Auger Operation:
functions of an optional attachment that is mounted to the
• Lever right ....... auger dig
vehicle and requires a hydraulic supply for operation.
• Lever left ......... auger retract
Some of the optional attachments that require auxiliary
hydraulics are: Side Tilt Carriage, Auger, and Swing Swing Carriage:
Carriage. • Lever right ....... swing right
When the control lever is moved to the right it • Lever left ......... swing left
will provide hydraulic system pressure through
the female disconnect coupling for the auxiliary
OH0431 attachment. Hydraulic fluid will return to the
tank through the male disconnect coupling.

Page 24 8042 Rev 3/04

When the control lever is moved to the left it will

provide hydraulic system pressure to the male
disconnect coupling for the auxiliary attach-
OH0451 ment. Hydraulic fluid will return to the tank
AUXILIARY ATTACHMENT through the female disconnect coupling.
CONTROL LEVER
The control lever will provide the following typical func-
tions for each specific attachment if they are connected
properly. Operation will be reversed if incorrectly con-
nected. We recommend reversing the disconnect
couplings on the hoses that are supplied with the attach-
Figure 12 OH0381 ment if operation is reversed.
Side Tilt Carriage Operation:
Auxiliary Attachment Control Lever • Lever right ....... tilt right
(See Figure 12) • Lever left ......... tilt left
The auxiliary attachment control lever controls the
Auger Operation:
functions of an optional attachment that is mounted to the
• Lever right ....... auger dig
vehicle and requires a hydraulic supply for operation.
• Lever left ......... auger retract
Some of the optional attachments that require auxiliary
hydraulics are: Side Tilt Carriage, Auger, and Swing Swing Carriage:
Carriage. • Lever right ....... swing right
When the control lever is moved to the right it • Lever left ......... swing left
will provide hydraulic system pressure through
the female disconnect coupling for the auxiliary
OH0431 attachment. Hydraulic fluid will return to the
tank through the male disconnect coupling.

Page 24 8042 Rev 3/04

 Walk-Around Inspection Normal Starting
1. Check the air cleaner restriction indicator for required
service.
2. Check and add engine oil if required. WARNING
DO NOT start the engine unless you are in the seat
3. Check cooling system overflow bottle for coolant.
with the seat belt fastened around you. Serious injury
Add coolant if required and remove debris or other
or death could result if the belt is not securely
foreign material from the radiator as necessary.
fastened.
4. Check hydraulic oil level sight gauge and add oil if

CAUTION
required.
5. Walk around the vehicle and check for leakage,
damaged or missing parts, proper tire inflation and The transmission requires 3 seconds immediately
hydrofill. Make necessary repairs before operating. after engine start for self-diagnostics. Always wait at
6. Check the condition of the rims, check for bent least 3 seconds after engine start before engaging
flanges and/or bead mounting areas. On three piece transmission. Failure to do so could damage the
rims, check the retaining ring on the backside of the transmission.
rim for wear or improper fit. Replace any damaged
parts before using the vehicle. 1. Using hand holds, enter the cab and adjust the
operator’s seat for comfortable operation.
2. Adjust mirrors to obtain best rear view from operator
position.

3. Fasten seat belt.

4. Check that the emergency brake switch is engaged.

8042 Rev 3/04 Page 25

Walk-Around Inspection Normal Starting

1. Check the air cleaner restriction indicator for required
service.
2. Check and add engine oil if required. WARNING
DO NOT start the engine unless you are in the seat
3. Check cooling system overflow bottle for coolant.
with the seat belt fastened around you. Serious injury
Add coolant if required and remove debris or other
or death could result if the belt is not securely
foreign material from the radiator as necessary.
fastened.
4. Check hydraulic oil level sight gauge and add oil if

CAUTION
required.
5. Walk around the vehicle and check for leakage,
damaged or missing parts, proper tire inflation and The transmission requires 3 seconds immediately
hydrofill. Make necessary repairs before operating. after engine start for self-diagnostics. Always wait at
6. Check the condition of the rims, check for bent least 3 seconds after engine start before engaging
flanges and/or bead mounting areas. On three piece transmission. Failure to do so could damage the
rims, check the retaining ring on the backside of the transmission.
rim for wear or improper fit. Replace any damaged
parts before using the vehicle. 1. Using hand holds, enter the cab and adjust the
operator’s seat for comfortable operation.
2. Adjust mirrors to obtain best rear view from operator
position.

3. Fasten seat belt.

4. Check that the emergency brake switch is engaged.

8042 Rev 3/04 Page 25

 5. Move travel and gear select lever to (N) NEUTRAL 10° F (-12° C). (Temperature ranges will vary when using
position and place the neutral lock lever to NEUTRAL different oil weights. Consult the engine manufacturer's
LOCK position. manual for other variables.)
6. Turn ignition switch to START position (fully clock- At temperatures below 10° F (-12° C), operate the engine
wise) to crank engine. Release key when engine at moderate speeds for 5 minutes before loads are
starts. If engine fails to start on first try, wait until applied.
engine and starter come to a complete stop before
cranking engine again. 1. Using hand holds, enter the cab and adjust the
operator’s seat for comfortable operation.

CAUTION WARNING
DO NOT crank starting motor continuously for more
DO NOT start the engine unless you are in the seat
than 15 seconds. This will avoid starter motor
with the seat belt fastened around you. Serious injury
overheating.
or death could result if the belt is not securely
7. After engine starts, run engine at partial throttle for fastened.
30 to 60 seconds before operating vehicle. Return to
idle before using travel and gear select lever. 2. Fasten seat belt.
8. Disengage emergency brake switch before you start 3. Check that the emergency brake switch is engaged.
operating. 4. Place the travel and gear select lever in
(N) NEUTRAL and move the neutral lock lever to
Cold Starting NEUTRAL LOCK position.
The engine on this vehicle is not normally equipped with 5. Depress the accelerator pedal to half speed.
a cold starting aid. Cold starting aids such as mechani-
cal or electrical ether metering equipment or block
heaters are recommended when temperatures are below

Page 26 8042 Rev 3/04

5. Move travel and gear select lever to (N) NEUTRAL 10° F (-12° C). (Temperature ranges will vary when using
position and place the neutral lock lever to NEUTRAL different oil weights. Consult the engine manufacturer's
LOCK position. manual for other variables.)
6. Turn ignition switch to START position (fully clock- At temperatures below 10° F (-12° C), operate the engine
wise) to crank engine. Release key when engine at moderate speeds for 5 minutes before loads are
starts. If engine fails to start on first try, wait until applied.
engine and starter come to a complete stop before
cranking engine again. 1. Using hand holds, enter the cab and adjust the
operator’s seat for comfortable operation.

CAUTION WARNING
DO NOT crank starting motor continuously for more
DO NOT start the engine unless you are in the seat
than 15 seconds. This will avoid starter motor
with the seat belt fastened around you. Serious injury
overheating.
or death could result if the belt is not securely
7. After engine starts, run engine at partial throttle for fastened.
30 to 60 seconds before operating vehicle. Return to
idle before using travel and gear select lever. 2. Fasten seat belt.
8. Disengage emergency brake switch before you start 3. Check that the emergency brake switch is engaged.
operating. 4. Place the travel and gear select lever in
(N) NEUTRAL and move the neutral lock lever to
Cold Starting NEUTRAL LOCK position.
The engine on this vehicle is not normally equipped with 5. Depress the accelerator pedal to half speed.
a cold starting aid. Cold starting aids such as mechani-
cal or electrical ether metering equipment or block
heaters are recommended when temperatures are below

Page 26 8042 Rev 3/04

 6. If using starting fluid with mechanical or electrical IMPORTANT: It is recommended that two people are
metering equipment: present when attempting to start the engine without me-
Turn the ignition switch to the START position to tered starting fluid equipment. One to operate the ignition
engage the starter motor and inject metered amounts switch the other to spray the fluid. Avoid soaking the air
of starting fluid. cleaner element with ether. This is extremely important
because a backfire of flame can completely destroy both
As the engine starts, stop injection of starting fluid
the primary and secondary air cleaner elements and other
and release the ignition key to the RUN position.
possible engine damage may occur.
Release the accelerator pedal to give a smooth idle
speed. Turn the ignition switch to the START position to
If using starting fluid without metering equipment: engage the starter motor. After the engine has
started to crank, not before, the other person can
spray starting fluid into the air cleaner intake.

WARNING As the engine starts, stop spraying starting fluid and

release the ignition key to the RUN position. Re-
NEVER use starting fluid near an open flame, or with lease the accelerator pedal to give a smooth idle
electric preheater or flame air heater equipment. speed.
Serious injury or death could result from explosion.
IMPORTANT: Never spray excessive amounts of ether!
DO NOT breathe starting fluid fumes. Serious injury Too much ether will wash oil off cylinder bores and cause
or death could result from toxic fumes. severe engine damage.
DO NOT use excessive amounts of starting fluid 7. The engine oil pressure warning light should turn
when starting an engine. Serious injury or death OFF within 5 seconds after the engine has started.
could result from a backfire of flame which could If the light remains ON, turn engine OFF immediately
ignite the starting fluid canister and cause an explo- and check oil level or change type of oil being used
sion. to a lighter weight oil. Consult engine manufacturer's
manual for other oils that can be used.

8042 Rev 3/04 Page 27

6. If using starting fluid with mechanical or electrical IMPORTANT: It is recommended that two people are
metering equipment: present when attempting to start the engine without me-
Turn the ignition switch to the START position to tered starting fluid equipment. One to operate the ignition
engage the starter motor and inject metered amounts switch the other to spray the fluid. Avoid soaking the air
of starting fluid. cleaner element with ether. This is extremely important
because a backfire of flame can completely destroy both
As the engine starts, stop injection of starting fluid
the primary and secondary air cleaner elements and other
and release the ignition key to the RUN position.
possible engine damage may occur.
Release the accelerator pedal to give a smooth idle
speed. Turn the ignition switch to the START position to
If using starting fluid without metering equipment: engage the starter motor. After the engine has
started to crank, not before, the other person can
spray starting fluid into the air cleaner intake.

WARNING As the engine starts, stop spraying starting fluid and

release the ignition key to the RUN position. Re-
NEVER use starting fluid near an open flame, or with lease the accelerator pedal to give a smooth idle
electric preheater or flame air heater equipment. speed.
Serious injury or death could result from explosion.
IMPORTANT: Never spray excessive amounts of ether!
DO NOT breathe starting fluid fumes. Serious injury Too much ether will wash oil off cylinder bores and cause
or death could result from toxic fumes. severe engine damage.
DO NOT use excessive amounts of starting fluid 7. The engine oil pressure warning light should turn
when starting an engine. Serious injury or death OFF within 5 seconds after the engine has started.
could result from a backfire of flame which could If the light remains ON, turn engine OFF immediately
ignite the starting fluid canister and cause an explo- and check oil level or change type of oil being used
sion. to a lighter weight oil. Consult engine manufacturer's
manual for other oils that can be used.

8042 Rev 3/04 Page 27

 1. The booster battery must be a 12 volt type. The
Jump Starting vehicle used for jump starting must have a negative
Jump starting at the battery or battery replacement is ground electrical system. To jump start the tele-
required when the battery is discharged to the point scopic handler, proceed as follows.
where the battery will not crank the starter. 2. Connect the positive (+) jumper cable to the positive
(+) post of the discharged battery.
3. Connect the other end of the same jumper cable to
WARNING the positive (+) post of the booster battery.
4. Connect one end of the second jumper cable to the
NEVER jump start the vehicle directly to the
negative (-) post of the booster battery.
starter or starter solenoid. Serious injury or death
could result from the vehicle moving forward or 5. Make the final jumper cable connection to the
backward and running over the person jump furthest ground point away from the discharged
starting the vehicle. battery.
6. Follow the steps in “Normal Starting.”
7. Remove the jumper cables in the reverse order of
WARNING their connection (i.e. negative cable ground connec-
tion first, etc.)
To avoid personal injury when jump starting with
another vehicle, be certain that the vehicles are
not touching. Never jump start a frozen battery as
it will explode. Keep sparks, flames and lighted
smoking materials away from the battery. Lead
acid batteries generate explosive gases when
charging. Wear safety glasses when working near
batteries.

Page 28 8042 Rev 3/04

1. The booster battery must be a 12 volt type. The

Jump Starting vehicle used for jump starting must have a negative
Jump starting at the battery or battery replacement is ground electrical system. To jump start the tele-
required when the battery is discharged to the point scopic handler, proceed as follows.
where the battery will not crank the starter. 2. Connect the positive (+) jumper cable to the positive
(+) post of the discharged battery.
3. Connect the other end of the same jumper cable to
WARNING the positive (+) post of the booster battery.
4. Connect one end of the second jumper cable to the
NEVER jump start the vehicle directly to the
negative (-) post of the booster battery.
starter or starter solenoid. Serious injury or death
could result from the vehicle moving forward or 5. Make the final jumper cable connection to the
backward and running over the person jump furthest ground point away from the discharged
starting the vehicle. battery.
6. Follow the steps in “Normal Starting.”
7. Remove the jumper cables in the reverse order of
WARNING their connection (i.e. negative cable ground connec-
tion first, etc.)
To avoid personal injury when jump starting with
another vehicle, be certain that the vehicles are
not touching. Never jump start a frozen battery as
it will explode. Keep sparks, flames and lighted
smoking materials away from the battery. Lead
acid batteries generate explosive gases when
charging. Wear safety glasses when working near
batteries.

Page 28 8042 Rev 3/04

 • Engaging the
Operating Emergency Brake
LOCKED MODE
Angle Of
Switch Stabil-TRAK
Understanding the Stabil-TRAK™ System Activation LOCKED
• Placing Travel and 40°
MODE
The following describes the three basic modes of the Gear Select Lever in Stabil-TRAK Light
"ON"
Stabil-TRAK system. (N) NEUTRAL
FREE PIVOT
• Depressing and MODE
Free Pivot Mode holding the Service Stabil-TRAK Light
FREE PIVOT MODE Brake Pedal "OFF"
With the boom below
Angle Of
40°, the Stabil-TRAK Stabil-TRAK The frame tilt func-
system is in the free Activation
40° tions slower than OH0710
pivot mode and the normal in this mode.
rear axle is allowed FINAL POSITIONING MODE
to pivot freely. Final PositioningMode
FREE PIVOT With the boom above
Angle Of
The frame tilt Stabil-TRAK
MODE Activation FINAL
POSITIONING
functions normally. Stabil-TRAK Light
40° and vehicle 40°
MODE
"OFF" traveling the Stabil- Stabil-TRAK Light
"OFF"
TRAK system is in
the final positioning FREE PIVOT
OH0700 mode. In this mode MODE
Locked Mode Stabil-TRAK Light
the rear axle is un- "OFF"
With the boom above 40°, the Stabil-TRAK locked and is allowed
system is in the locked mode and the rear axle is to pivot, but will re- Travel

locked so it is rigid with the frame. This mode is spond SLOWLY to OH0721

activated by one or more of the following functions: changes in terrain.

The frame tilt functions normally in this mode.

8042 Rev 3/04 Page 29

• Engaging the
Operating Emergency Brake
LOCKED MODE
Angle Of
Switch Stabil-TRAK
Understanding the Stabil-TRAK™ System Activation LOCKED
• Placing Travel and 40°
MODE
The following describes the three basic modes of the Gear Select Lever in Stabil-TRAK Light
"ON"
Stabil-TRAK system. (N) NEUTRAL
FREE PIVOT
• Depressing and MODE
Free Pivot Mode holding the Service Stabil-TRAK Light
FREE PIVOT MODE Brake Pedal "OFF"
With the boom below
Angle Of
40°, the Stabil-TRAK Stabil-TRAK The frame tilt func-
system is in the free Activation
40° tions slower than OH0710
pivot mode and the normal in this mode.
rear axle is allowed FINAL POSITIONING MODE
to pivot freely. Final PositioningMode
FREE PIVOT With the boom above
Angle Of
The frame tilt Stabil-TRAK
MODE Activation FINAL
POSITIONING
functions normally. Stabil-TRAK Light
40° and vehicle 40°
MODE
"OFF" traveling the Stabil- Stabil-TRAK Light
"OFF"
TRAK system is in
the final positioning FREE PIVOT
OH0700 mode. In this mode MODE
Locked Mode Stabil-TRAK Light
the rear axle is un- "OFF"
With the boom above 40°, the Stabil-TRAK locked and is allowed
system is in the locked mode and the rear axle is to pivot, but will re- Travel

locked so it is rigid with the frame. This mode is spond SLOWLY to OH0721

activated by one or more of the following functions: changes in terrain.

The frame tilt functions normally in this mode.

8042 Rev 3/04 Page 29

 It is important that you regularly check that this system IMPORTANT: Check warning lights frequently during
is functioning properly. Refer to the test procedure later operation. Any abnormal indications or vehicle malfunction
in this manual for proper system function. should be corrected as soon as possible.

CAUTION Changing Travel Direction

1. Stop the vehicle.
The transmission requires 3 seconds immediately
2. Move travel select lever to opposite direction,
after engine start for self-diagnostics. Always wait
(R) REVERSE or (F) FORWARD.
at least 3 seconds after engine start before engag-
ing transmission. Shifting Gears
Starting Travel 1. Rotate the twist grip of the gear select lever to the
next desired gear.
1. Enter operator cab, fasten seat belt, start engine and
disengage emergency brake switch. NOTE: Shifting to the next higher gear may be done while
the vehicle is in motion.
2. Rotate the gear select lever to the desired gear.
IMPORTANT: When downshifting, allow the engine speed
3. Move travel select lever to (F) FORWARD or
to slow down before shifting to the next lower gear.
(R) REVERSE as needed.
4. Use accelerator pedal to control ground speed. Stopping Travel
5. Avoid operating in too high a gear when moving a 1. Apply service brakes and downshift to lower gear as
heavy load as this may cause excessive “lugging.” necessary to slow the vehicle until it comes to a
This occurs when the engine will not respond to a complete stop.
throttle increase. Use a lower gear when moving a 2. Move travel and gear select lever to (N) NEUTRAL
heavy load; a higher gear when moving a light load. for longer stops, place neutral lock lever to
Selecting the correct gear ratio will save fuel and NEUTRAL LOCK position and ENGAGE the emer-
prolong engine life. gency brake switch.

Page 30 8042 Rev 3/04

It is important that you regularly check that this system IMPORTANT: Check warning lights frequently during
is functioning properly. Refer to the test procedure later operation. Any abnormal indications or vehicle malfunction
in this manual for proper system function. should be corrected as soon as possible.

CAUTION Changing Travel Direction

1. Stop the vehicle.
The transmission requires 3 seconds immediately
2. Move travel select lever to opposite direction,
after engine start for self-diagnostics. Always wait
(R) REVERSE or (F) FORWARD.
at least 3 seconds after engine start before engag-
ing transmission. Shifting Gears
Starting Travel 1. Rotate the twist grip of the gear select lever to the
next desired gear.
1. Enter operator cab, fasten seat belt, start engine and
disengage emergency brake switch. NOTE: Shifting to the next higher gear may be done while
the vehicle is in motion.
2. Rotate the gear select lever to the desired gear.
IMPORTANT: When downshifting, allow the engine speed
3. Move travel select lever to (F) FORWARD or
to slow down before shifting to the next lower gear.
(R) REVERSE as needed.
4. Use accelerator pedal to control ground speed. Stopping Travel
5. Avoid operating in too high a gear when moving a 1. Apply service brakes and downshift to lower gear as
heavy load as this may cause excessive “lugging.” necessary to slow the vehicle until it comes to a
This occurs when the engine will not respond to a complete stop.
throttle increase. Use a lower gear when moving a 2. Move travel and gear select lever to (N) NEUTRAL
heavy load; a higher gear when moving a light load. for longer stops, place neutral lock lever to
Selecting the correct gear ratio will save fuel and NEUTRAL LOCK position and ENGAGE the emer-
prolong engine life. gency brake switch.

Page 30 8042 Rev 3/04

Steering 1. Four Wheel Steering (See Figure 13)
The vehicle can be operated in three steering modes
as selected at the steering select switch on the
instrument panel: four wheel steer, two wheel steer
and crab steer. WARNING
NOTE: DO NOT change steer select switch unless NEVER use the four wheel steer mode when traveling
all tires are in the straight ahead position. If tires are at high speed. Rapid turning in this mode will cause
not “straight ahead”, steering may become out-of- tipover. Use only the two wheel steer mode at high
phase, making it necessary to perform the four wheel speeds and slow vehicle when turning.
steer indexing procedure which follows.
Four Wheel Steer Indexing Procedure
1. With the steering select switch in the Four Wheel
Steer position, turn the steering wheel full left.
While holding the steering wheel full left, toggle
the steer select switch to the Front Wheel Steer
position and steer the front wheels back to
OH0070
center. Toggle the steer select switch back to Figure 13
Four Wheel Steer position and turn the steering
wheel full left. Toggle the steer select switch The front wheels will steer in the direction that the
back to Front Wheel Steer position and steer the steering wheel is turned; the rear wheels will steer in
front wheels full left. Toggle the switch to the the opposite direction. This mode allows an ex-
Four Wheel Steer position and return to center. tremely short turning radius. It also enables the rear
2. The vehicle should now be properly indexed in wheels to follow the tracking of front wheels which is
Four Wheel Steering. If the wheels are still out- an advantage in mud or sand conditions.
of-phase, repeat step 1 again.

8042 Rev 3/04 Page 31

Steering 1. Four Wheel Steering (See Figure 13)

The vehicle can be operated in three steering modes
as selected at the steering select switch on the
instrument panel: four wheel steer, two wheel steer
and crab steer. WARNING
NOTE: DO NOT change steer select switch unless NEVER use the four wheel steer mode when traveling
all tires are in the straight ahead position. If tires are at high speed. Rapid turning in this mode will cause
not “straight ahead”, steering may become out-of- tipover. Use only the two wheel steer mode at high
phase, making it necessary to perform the four wheel speeds and slow vehicle when turning.
steer indexing procedure which follows.
Four Wheel Steer Indexing Procedure
1. With the steering select switch in the Four Wheel
Steer position, turn the steering wheel full left.
While holding the steering wheel full left, toggle
the steer select switch to the Front Wheel Steer
position and steer the front wheels back to
OH0070
center. Toggle the steer select switch back to Figure 13
Four Wheel Steer position and turn the steering
wheel full left. Toggle the steer select switch The front wheels will steer in the direction that the
back to Front Wheel Steer position and steer the steering wheel is turned; the rear wheels will steer in
front wheels full left. Toggle the switch to the the opposite direction. This mode allows an ex-
Four Wheel Steer position and return to center. tremely short turning radius. It also enables the rear
2. The vehicle should now be properly indexed in wheels to follow the tracking of front wheels which is
Four Wheel Steering. If the wheels are still out- an advantage in mud or sand conditions.
of-phase, repeat step 1 again.

8042 Rev 3/04 Page 31

 2. Two Wheel Steering (See Figure 14) 3. Crab Steering (See Figure 15)
The front wheels will steer in the direction that the All wheels will steer in same direction. This mode
steering wheel is turned. The rear wheels will remain permits the operator to move the vehicle sideways
in the fixed forward position. This mode is used for toward the landing point of the load. This is espe-
on-highway travel or at higher speeds. cially helpful in tight quarters on a job, where there is
not enough space to move a conventional telescopic
handler back and forth several times in order to line
up at the exact spot in front of the loading location.

Figure 14 OH0080

Figure 15 OH0060

Page 32 8042 Rev 3/04

2. Two Wheel Steering (See Figure 14) 3. Crab Steering (See Figure 15)
The front wheels will steer in the direction that the All wheels will steer in same direction. This mode
steering wheel is turned. The rear wheels will remain permits the operator to move the vehicle sideways
in the fixed forward position. This mode is used for toward the landing point of the load. This is espe-
on-highway travel or at higher speeds. cially helpful in tight quarters on a job, where there is
not enough space to move a conventional telescopic
handler back and forth several times in order to line
up at the exact spot in front of the loading location.

Figure 14 OH0080

Figure 15 OH0060

Page 32 8042 Rev 3/04

 CAUTION
The forks extend beyond the end of the carriage. The
operator must be aware of the maximum sweep of the
forks when turning and allow for adequate clearance
between the forks, personnel and other objects (See
Figure 16).

CENTER OF
TURNING RADIUS

VEHICLE
TURNING RADIUS

MAXIMUM
FORK SWEEP

Figure 16 OH0090

8042 Rev 3/04 Page 33

CAUTION
The forks extend beyond the end of the carriage. The
operator must be aware of the maximum sweep of the
forks when turning and allow for adequate clearance
between the forks, personnel and other objects (See
Figure 16).

CENTER OF
TURNING RADIUS

VEHICLE
TURNING RADIUS

MAXIMUM
FORK SWEEP

Figure 16 OH0090

8042 Rev 3/04 Page 33

Leveling Frame
When placing a load while on a slope, use the frame
PIN LOCK
tilt control lever to keep the load level. The operator LEVER
should observe the frame level indicator to assure
that the load is level at all times.

DANGER
Frame tilting with the boom raised above horizontal
can cause tipover resulting in death or serious injury.
Always use the frame tilt to level the vehicle before
raising the boom above horizontal. If the vehicle
cannot be leveled using the frame tilt, reposition the
vehicle.
QUICK ATTACH PIN
Quick Attach (See Figure 17)
OS0331
This vehicle is equipped with a quick attach system for Figure 17
easy attachment changing.
3. Extend the boom about 10 feet and tilt the carriage
Quick Attach Removal backward.
1. Park the vehicle on level ground. 4. Exit the vehicle using the hand holds.
2. Place travel and gear select lever in (N) NEUTRAL, NOTE: Before removing a carriage type attachment,
move neutral lock lever to NEUTRAL LOCK position spread the forks out on the carriage shaft. This will give
and engage the emergency brake switch. the carriage adequate support to stand alone when it is
removed from the boom.

Page 34 8042 Rev 3/04

Leveling Frame
When placing a load while on a slope, use the frame
PIN LOCK
tilt control lever to keep the load level. The operator LEVER
should observe the frame level indicator to assure
that the load is level at all times.

DANGER
Frame tilting with the boom raised above horizontal
can cause tipover resulting in death or serious injury.
Always use the frame tilt to level the vehicle before
raising the boom above horizontal. If the vehicle
cannot be leveled using the frame tilt, reposition the
vehicle.
QUICK ATTACH PIN
Quick Attach (See Figure 17)
OS0331
This vehicle is equipped with a quick attach system for Figure 17
easy attachment changing.
3. Extend the boom about 10 feet and tilt the carriage
Quick Attach Removal backward.
1. Park the vehicle on level ground. 4. Exit the vehicle using the hand holds.
2. Place travel and gear select lever in (N) NEUTRAL, NOTE: Before removing a carriage type attachment,
move neutral lock lever to NEUTRAL LOCK position spread the forks out on the carriage shaft. This will give
and engage the emergency brake switch. the carriage adequate support to stand alone when it is
removed from the boom.

Page 34 8042 Rev 3/04

 5. Raise the quick attach pin lock lever and pull out 5. Pull the attachment tilt control lever backward until
the pin at the bottom of the quick attach link. the front of the attachment starts to raise. The
quick attach link should be tight up against the rear
6. Return to the operator’s compartment, lower the of the attachment and the holes in the link and the
attachment to the ground in a level position, and attachment should be aligned.
push the attachment tilt lever forward. This will
rotate the quick attach link back away from the 6. Place travel select lever in (N) NEUTRAL, move
attachment. neutral lock lever to NEUTRAL LOCK position,
engage emergency brake switch and exit the
7. Lower, then retract the boom until the boom hook telescopic handler using the hand holds.
pins have disconnected from the attachment.
7. Lift lever. Insert the quick attach pin completely
Quick Attach Reconnect through the attachment and quick attach link. Be
1. Be sure that you are performing this procedure on sure that the quick attach lock lever has lowered
level ground. Position the vehicle directly behind and seated itself into the groove in the quick attach
the attachment to be mounted. pin.

2. Push the attachment tilt control lever forward to

3.
rotate the quick attach link back.
Extend the boom approximately 10 feet and drive
WARNING
DO NOT operate this machine unless you are in the
the vehicle forward until the boom hook pins are
seat with the seat belt fastened around you. Serious
below and between the two hooks on the attach-
injury or death could result if the belt is not securely
ment.
fastened.
4. Raise the boom until the boom hook pins have
seated fully in the hooks on the attachment. 8. Return to the operator’s compartment, fasten seat
belt and resume operation.

8042 Rev 3/04 Page 35

5. Raise the quick attach pin lock lever and pull out 5. Pull the attachment tilt control lever backward until
the pin at the bottom of the quick attach link. the front of the attachment starts to raise. The
quick attach link should be tight up against the rear
6. Return to the operator’s compartment, lower the of the attachment and the holes in the link and the
attachment to the ground in a level position, and attachment should be aligned.
push the attachment tilt lever forward. This will
rotate the quick attach link back away from the 6. Place travel select lever in (N) NEUTRAL, move
attachment. neutral lock lever to NEUTRAL LOCK position,
engage emergency brake switch and exit the
7. Lower, then retract the boom until the boom hook telescopic handler using the hand holds.
pins have disconnected from the attachment.
7. Lift lever. Insert the quick attach pin completely
Quick Attach Reconnect through the attachment and quick attach link. Be
1. Be sure that you are performing this procedure on sure that the quick attach lock lever has lowered
level ground. Position the vehicle directly behind and seated itself into the groove in the quick attach
the attachment to be mounted. pin.

2. Push the attachment tilt control lever forward to

3.
rotate the quick attach link back.
Extend the boom approximately 10 feet and drive
WARNING
DO NOT operate this machine unless you are in the
the vehicle forward until the boom hook pins are
seat with the seat belt fastened around you. Serious
below and between the two hooks on the attach-
injury or death could result if the belt is not securely
ment.
fastened.
4. Raise the boom until the boom hook pins have
seated fully in the hooks on the attachment. 8. Return to the operator’s compartment, fasten seat
belt and resume operation.

8042 Rev 3/04 Page 35

 • DO NOT raise the boom above 60° for steps
Stabil-TRAK™ System Test 3 thru 6.
IMPORTANT: It is important for the operator to know • DO NOT raise the boom above 45° for steps
that the Stabil-TRAK system is active and functioning 7 thru 9.
properly.
• Follow steps 1 thru 9 of the Stabil-TRAK system
test procedure exactly as written.
DANGER IMPORTANT: If the Stabil-TRAK light goes OFF and the
Vehicle tipover can result in death or serious injury. front left tire lowers to the ground at any time during steps
Always operate vehicle with rear stabilizer cylinder in 4 thru 7, the test was not performed properly or the Stabil-
place and functioning properly. TRAK system is not functioning properly.
DO NOT use the vehicle if the Stabil-TRAK system is Carefully repeat the steps starting with step 1. If the
not functioning properly. Stabil-TRAK light goes OFF and the front left tire lowers
to the ground consistently during steps 4 thru 7, the
To test the function of the Stabil-TRAK system, read the Stabil-TRAK system is not functioning properly and the
Stabil-TRAK system test instructions and follow steps 1 test should be stopped immediately. DO NOT use the
thru 9 of the Stabil-TRAK system test procedure. vehicle if the Stabil-TRAK system is not functioning
Stabil-TRAK™ System Test Instructions properly. Contact your local Sky TRAK Distributor
immediately to repair the system.
• Test the Stabil-TRAK system with the vehicle on a
level surface.
• Remove any attachment from the quick attach
before performing the test.
• Perform the test with the boom fully retracted.
DO NOT extend the boom at any time during the
test.

Page 36 8042 Rev 3/04

• DO NOT raise the boom above 60° for steps

Stabil-TRAK™ System Test 3 thru 6.
IMPORTANT: It is important for the operator to know • DO NOT raise the boom above 45° for steps
that the Stabil-TRAK system is active and functioning 7 thru 9.
properly.
• Follow steps 1 thru 9 of the Stabil-TRAK system
test procedure exactly as written.
DANGER IMPORTANT: If the Stabil-TRAK light goes OFF and the
Vehicle tipover can result in death or serious injury. front left tire lowers to the ground at any time during steps
Always operate vehicle with rear stabilizer cylinder in 4 thru 7, the test was not performed properly or the Stabil-
place and functioning properly. TRAK system is not functioning properly.
DO NOT use the vehicle if the Stabil-TRAK system is Carefully repeat the steps starting with step 1. If the
not functioning properly. Stabil-TRAK light goes OFF and the front left tire lowers
to the ground consistently during steps 4 thru 7, the
To test the function of the Stabil-TRAK system, read the Stabil-TRAK system is not functioning properly and the
Stabil-TRAK system test instructions and follow steps 1 test should be stopped immediately. DO NOT use the
thru 9 of the Stabil-TRAK system test procedure. vehicle if the Stabil-TRAK system is not functioning
Stabil-TRAK™ System Test Instructions properly. Contact your local Sky TRAK Distributor
immediately to repair the system.
• Test the Stabil-TRAK system with the vehicle on a
level surface.
• Remove any attachment from the quick attach
before performing the test.
• Perform the test with the boom fully retracted.
DO NOT extend the boom at any time during the
test.

Page 36 8042 Rev 3/04

 IMPORTANT: Perform procedures 4 thru 9 with the

WARNING engine rpm at idle.

4. With the service brake pedal depressed, move the
travel select lever to the (R) REVERSE position.
DO NOT operate this vehicle unless you are in the
seat with the seat belt fastened around you. Ease your foot off the service brake pedal and
Serious injury or death could result if the belt is not increase engine RPM slightly if necessary just
securely fastened. enough to back the vehicle off of the block, while
keeping the service brake pedal partially de-
Stabil-TRAK™ System Test Procedure pressed so that the Stabil-TRAK light remains ON.
1. Fasten seat belt and place the vehicle on a level The rear axle should remain locked while backing
surface with 0° frame tilt angle, no load on the off of the block and the front left tire should remain
forks, boom fully retracted and horizontal. Check off the ground.
to be sure the Stabil-TRAK light is OFF. 5. While keeping the service brake pedal depressed,
2. Locate an eight inch wood or concrete block in move the travel select lever to the (N) NEUTRAL
front of the left front tire and drive the vehicle up on position and take your foot off of the service brake
the block. Frame tilt the vehicle back to 0°. pedal. The rear axle should remain locked, the
Stabil-TRAK light should remain ON, and the front
3. With the service brake pedal depressed, the
left tire should remain off the ground.
emergency brake switch OFF, move the travel
select lever to the (N) NEUTRAL position and raise 6. With the travel select lever in the (N) NEUTRAL
the boom to exactly 60°. The Stabil-TRAK light position, engage the emergency brake switch and
should come ON when the boom angle is at about move the travel select lever to the (F) FORWARD
40° and remain ON. position. The rear axle should remain locked, the
Stabil-TRAK light should remain ON, and the front
left tire should remain off the ground.

8042 Rev 3/04 Page 37

IMPORTANT: Perform procedures 4 thru 9 with the

WARNING engine rpm at idle.

4. With the service brake pedal depressed, move the
travel select lever to the (R) REVERSE position.
DO NOT operate this vehicle unless you are in the
seat with the seat belt fastened around you. Ease your foot off the service brake pedal and
Serious injury or death could result if the belt is not increase engine RPM slightly if necessary just
securely fastened. enough to back the vehicle off of the block, while
keeping the service brake pedal partially de-
Stabil-TRAK™ System Test Procedure pressed so that the Stabil-TRAK light remains ON.
1. Fasten seat belt and place the vehicle on a level The rear axle should remain locked while backing
surface with 0° frame tilt angle, no load on the off of the block and the front left tire should remain
forks, boom fully retracted and horizontal. Check off the ground.
to be sure the Stabil-TRAK light is OFF. 5. While keeping the service brake pedal depressed,
2. Locate an eight inch wood or concrete block in move the travel select lever to the (N) NEUTRAL
front of the left front tire and drive the vehicle up on position and take your foot off of the service brake
the block. Frame tilt the vehicle back to 0°. pedal. The rear axle should remain locked, the
Stabil-TRAK light should remain ON, and the front
3. With the service brake pedal depressed, the
left tire should remain off the ground.
emergency brake switch OFF, move the travel
select lever to the (N) NEUTRAL position and raise 6. With the travel select lever in the (N) NEUTRAL
the boom to exactly 60°. The Stabil-TRAK light position, engage the emergency brake switch and
should come ON when the boom angle is at about move the travel select lever to the (F) FORWARD
40° and remain ON. position. The rear axle should remain locked, the
Stabil-TRAK light should remain ON, and the front
left tire should remain off the ground.

8042 Rev 3/04 Page 37

 7. With the emergency brake switch ON, move the 9. With the service brake pedal depressed, boom
travel select lever to the (N) NEUTRAL position, angle at exactly 45°, move the gear select lever to
and lower the boom to exactly 45°. Frame tilt the (3) third and the travel select lever to
vehicle no more than 5° to the left and then no (F) FORWARD. Release the service brake pedal
more than 5° to the right. The vehicle should to deactivate the Stabil-TRAK system and the
frame tilt slowly to the left and then to the right. Stabil-TRAK light should go OFF. Slowly drive the
The Stabil-TRAK light should remain ON, and the vehicle forward against the block to stop the
left front tire should remain off the ground. The vehicle from moving forward. With the front left tire
front left tire should not raise or lower when frame against the block, frame tilt the vehicle no more
tilting. Leave the vehicle frame tilted to the right 1° than 5° in both directions while checking that the
to 2°. front tires remain on the ground. It is normal for
the left front tire to raise slightly when frame tilting
8. Depress the service brake pedal. Disengage the
to the left and for the right front tire to raise slightly
emergency brake switch and move the travel
when frame tilting to the right, but the tires should
select lever to the (R) REVERSE position.
immediately lower when the frame tilt function is
Release the service brake pedal to deactivate the
stopped. The tires should not come completely off
Stabil-TRAK system and the Stabil-TRAK light
the ground during this step. Frame tilt the vehicle
should go OFF. The left front tire should return to
back to zero. Depress the service brake pedal,
the ground while the vehicle travels in reverse.
shift the travel select lever to (N) NEUTRAL and
Depress the service brake pedal to stop the
lower the boom.
vehicle.
If steps 1 thru 9 prove positive, the Stabil-TRAK system
is functioning properly and the vehicle can be returned to
service. If any of these steps indicate that the Stabil-
TRAK system is not functioning properly, contact your
Sky Trak Distributor immediately to repair the system.

Page 38 8042 Rev 3/04

7. With the emergency brake switch ON, move the 9. With the service brake pedal depressed, boom
travel select lever to the (N) NEUTRAL position, angle at exactly 45°, move the gear select lever to
and lower the boom to exactly 45°. Frame tilt the (3) third and the travel select lever to
vehicle no more than 5° to the left and then no (F) FORWARD. Release the service brake pedal
more than 5° to the right. The vehicle should to deactivate the Stabil-TRAK system and the
frame tilt slowly to the left and then to the right. Stabil-TRAK light should go OFF. Slowly drive the
The Stabil-TRAK light should remain ON, and the vehicle forward against the block to stop the
left front tire should remain off the ground. The vehicle from moving forward. With the front left tire
front left tire should not raise or lower when frame against the block, frame tilt the vehicle no more
tilting. Leave the vehicle frame tilted to the right 1° than 5° in both directions while checking that the
to 2°. front tires remain on the ground. It is normal for
the left front tire to raise slightly when frame tilting
8. Depress the service brake pedal. Disengage the
to the left and for the right front tire to raise slightly
emergency brake switch and move the travel
when frame tilting to the right, but the tires should
select lever to the (R) REVERSE position.
immediately lower when the frame tilt function is
Release the service brake pedal to deactivate the
stopped. The tires should not come completely off
Stabil-TRAK system and the Stabil-TRAK light
the ground during this step. Frame tilt the vehicle
should go OFF. The left front tire should return to
back to zero. Depress the service brake pedal,
the ground while the vehicle travels in reverse.
shift the travel select lever to (N) NEUTRAL and
Depress the service brake pedal to stop the
lower the boom.
vehicle.
If steps 1 thru 9 prove positive, the Stabil-TRAK system
is functioning properly and the vehicle can be returned to
service. If any of these steps indicate that the Stabil-
TRAK system is not functioning properly, contact your
Sky Trak Distributor immediately to repair the system.

Page 38 8042 Rev 3/04

 To accurately use the capacity chart, the operator must
Using The Capacity Chart first determine the following three things:
The capacity chart is located on the right side wall of the 1. Weight of the load being lifted.
operator’s compartment. The chart is provided to assist
2. Height of the structure where load is to be placed.
the operator in determining how far in front, how high and
at what angle a specific load weight can be safely 3. Distance where the load will ultimately be placed in
handled with this vehicle. front of the vehicle.

This vehicle is equipped with two major indicators that

will assist the operator in determining how to accurately
use the capacity chart. These components are the boom
extend letters and the boom angle indicator.
WARNING
DO NOT exceed rated capacities. Any attempt to lift
As the boom is extended, boom extend letters will appear or carry loads in excess of those shown on the
on the left side of the boom visible to the operator. The capacity chart in the operator's compartment may
letters are graduated in four foot increments. These cause vehicle tipover, loss of load or structural dam-
letters indicate the point of boom extension and corre- age which could result in death or serious injury.
spond to the capacity chart. For example, when the
letter “A” first appears, the boom is at the point of boom
extension corresponding to the arc of line “A” throughout
the entire capacity chart (Figure 18).
The boom angle indicator located on the left side of the
boom indicates the angle of the boom as shown in the
capacity chart.

8042 Rev 3/04 Page 39

To accurately use the capacity chart, the operator must

Using The Capacity Chart first determine the following three things:
The capacity chart is located on the right side wall of the 1. Weight of the load being lifted.
operator’s compartment. The chart is provided to assist
2. Height of the structure where load is to be placed.
the operator in determining how far in front, how high and
at what angle a specific load weight can be safely 3. Distance where the load will ultimately be placed in
handled with this vehicle. front of the vehicle.

This vehicle is equipped with two major indicators that

will assist the operator in determining how to accurately
use the capacity chart. These components are the boom
extend letters and the boom angle indicator.
WARNING
DO NOT exceed rated capacities. Any attempt to lift
As the boom is extended, boom extend letters will appear or carry loads in excess of those shown on the
on the left side of the boom visible to the operator. The capacity chart in the operator's compartment may
letters are graduated in four foot increments. These cause vehicle tipover, loss of load or structural dam-
letters indicate the point of boom extension and corre- age which could result in death or serious injury.
spond to the capacity chart. For example, when the
letter “A” first appears, the boom is at the point of boom
extension corresponding to the arc of line “A” throughout
the entire capacity chart (Figure 18).
The boom angle indicator located on the left side of the
boom indicates the angle of the boom as shown in the
capacity chart.

8042 Rev 3/04 Page 39

 Reading the chart —
EXAMPLE:
1. The operator has placed the load onto the forks,
fully retracted the boom, positioned the vehicle 28 24 20 16 12 8 4 0 FT
(8,5) (7,3) (6,1) (4,9) (3,7) (2,4) (1,2) (0 M)
perpendicular to the structure and leveled the 44
68°
(13,4)
vehicle.
40 60° E
(12,2) 13.00 – 24 12 PLY TIRES
2. The operator then determines that: 36 D
at 70 psi (482 kPa)

(11,0) 50° 13.00 R 24 ONE STAR RADIALS

• The load weight is 4000 pounds (1810 kg). 32 C at 80 psi (551 kPa)
(9,8)
• The height of the structure the load is to be 40° 8000 LBS 15.5 – 25 12 PLY TIRES
28 3630 KG B at 58 psi (400 kPa)
(8,5)
placed upon is 26 feet (7,9 meters) from ground 6000 LBS A
17.5 – 25 12 PLY TIRES
2720 KG at 51 psi (352 kPa)
24
level. (7,3) 30°
Hydrofill per operators manual
20
4000 LBS
• The distance where the load will ultimately be (6,1) 1810 KG Load Ratings per
ASME B56.6b — 1998
placed in front of the vehicle is 17 feet 16 20° 3000 LBS
(4,9) 1360 KG
(5,2 meters) from the front of the front tires.
12
(3,7) 2500 LBS
3. After applying the height of the structure and the 10° 1130 KG
8
(2,4)
distance of load placement away from the vehicle 1800 LBS
4 820 KG
to the capacity chart (Figure 18), the operator (1,2)
0°
knows that it will be safe to place the load if the 0 FT
(0 M)
boom extend letter “D” has appeared and the boom
-4 -4°
angle indicator reading does not go below approxi- (-1,2) LOAD CENTER
24 in (610 mm)
mately 40°. This condition is however, a maximum 22 20 17 13 10
(6,7) (6,1) (5,2) (4,0) (3,1)
limit for this weight, height and distance away from
the vehicle. The operator should move the vehicle
closer to the structure to assure that the vehicle will
not exceed the maximum limits for placing the load. Figure 18 OH0224

Page 40 8042 Rev 3/04

Reading the chart —

EXAMPLE:
1. The operator has placed the load onto the forks,
fully retracted the boom, positioned the vehicle 28 24 20 16 12 8 4 0 FT
(8,5) (7,3) (6,1) (4,9) (3,7) (2,4) (1,2) (0 M)
perpendicular to the structure and leveled the 44
68°
(13,4)
vehicle.
40 60° E
(12,2) 13.00 – 24 12 PLY TIRES
2. The operator then determines that: 36 D
at 70 psi (482 kPa)

(11,0) 50° 13.00 R 24 ONE STAR RADIALS

• The load weight is 4000 pounds (1810 kg). 32 C at 80 psi (551 kPa)
(9,8)
• The height of the structure the load is to be 40° 8000 LBS 15.5 – 25 12 PLY TIRES
28 3630 KG B at 58 psi (400 kPa)
(8,5)
placed upon is 26 feet (7,9 meters) from ground 6000 LBS A
17.5 – 25 12 PLY TIRES
2720 KG at 51 psi (352 kPa)
24
level. (7,3) 30°
Hydrofill per operators manual
20
4000 LBS
• The distance where the load will ultimately be (6,1) 1810 KG Load Ratings per
ASME B56.6b — 1998
placed in front of the vehicle is 17 feet 16 20° 3000 LBS
(4,9) 1360 KG
(5,2 meters) from the front of the front tires.
12
(3,7) 2500 LBS
3. After applying the height of the structure and the 10° 1130 KG
8
(2,4)
distance of load placement away from the vehicle 1800 LBS
4 820 KG
to the capacity chart (Figure 18), the operator (1,2)
0°
knows that it will be safe to place the load if the 0 FT
(0 M)
boom extend letter “D” has appeared and the boom
-4 -4°
angle indicator reading does not go below approxi- (-1,2) LOAD CENTER
24 in (610 mm)
mately 40°. This condition is however, a maximum 22 20 17 13 10
(6,7) (6,1) (5,2) (4,0) (3,1)
limit for this weight, height and distance away from
the vehicle. The operator should move the vehicle
closer to the structure to assure that the vehicle will
not exceed the maximum limits for placing the load. Figure 18 OH0224

Page 40 8042 Rev 3/04

 LOAD
AD
RANGE 1 2 3 4 5 6
4000 lbs (1810 kg)
1300 lbs 2000 lbs 3000 lbs
(590 kg) (910 kg) (1360 kg) 4000 lbs 6000 lbs 8000 lbs
(1810 kg) (2720 kg) (3630 kg)
28 24 20 16 12 8 4 0 ft
(8,5) (7,3) (6,1) (4,9) (3,7) (2,4) (1,2) (0 m)
SWING CARRIAGE
CARRIA
40
(12,2)
E ATTACHMENT ON
36
(11,0)
32
D

C
8042
(9,8) 13.00 – 24 12 PLY TIRES
at 70 psi (482 kPa)
28 B
(8,5) 13.00 R 24 ONE STAR RADIALS
24 6 A at 80 psi (551 kPa)
(7,3)

20 5 68°
15.5 – 25 12 PLY TIRES
(6,1)
at 58 psi (400 kPa)
60°
16
4 50° 17.5 – 25 12 PLY TIRES
(4,9) at 51 psi (352 kPa)
12
3 40°
(3,7) 30°
Hydrofill per operators manual
8
2 Load Ratings per
(2,4) 20°
ASME B56.6b-1998
4
1 10°
(1,2)
0°
0 ft
(0 m) -8 ° LOAD CENTER
-4 24 in (610 mm)
-(1,2)
27.5 22.5 18.5 16 12 9.5
(8,4) (6,9) (5,6) (4,9) (3,7) (2,9)

OH0732 OH0752

8042 Rev 3/04 Page 41

LOAD
AD
RANGE 1 2 3 4 5 6
4000 lbs (1810 kg)
1300 lbs 2000 lbs 3000 lbs
(590 kg) (910 kg) (1360 kg) 4000 lbs 6000 lbs 8000 lbs
(1810 kg) (2720 kg) (3630 kg)
28 24 20 16 12 8 4 0 ft
(8,5) (7,3) (6,1) (4,9) (3,7) (2,4) (1,2) (0 m)
SWING CARRIAGE
CARRIA
40
(12,2)
E ATTACHMENT ON
36
(11,0)
32
D

C
8042
(9,8) 13.00 – 24 12 PLY TIRES
at 70 psi (482 kPa)
28 B
(8,5) 13.00 R 24 ONE STAR RADIALS
24 6 A at 80 psi (551 kPa)
(7,3)

20 5 68°
15.5 – 25 12 PLY TIRES
(6,1)
at 58 psi (400 kPa)
60°
16
4 50° 17.5 – 25 12 PLY TIRES
(4,9) at 51 psi (352 kPa)
12
3 40°
(3,7) 30°
Hydrofill per operators manual
8
2 Load Ratings per
(2,4) 20°
ASME B56.6b-1998
4
1 10°
(1,2)
0°
0 ft
(0 m) -8 ° LOAD CENTER
-4 24 in (610 mm)
-(1,2)
27.5 22.5 18.5 16 12 9.5
(8,4) (6,9) (5,6) (4,9) (3,7) (2,9)

OH0732 OH0752

8042 Rev 3/04 Page 41

 Fork Ratings
All forks that can be used on this vehicle are marked
SIDE TILT CARRIAGE with a maximum load capacity rating. This rating can
ATTACHMENT ON be found stamped on the left edge of the fork just below
8042
28 24 20 16 12 8 4 0 FT
(8,5) (7,3) (6,1) (4,9) (3,7) (2,4) (1,2) (0 M)
44
(13,4)
the fork pivot shaft (See Figure 19). This rating is listed
40 60° in U.S. pounds and based upon a 24" (610 mm) load
(12,2) E 13.00 – 24 12 PLY TIRES
at 70 psi (482 kPa)
center. For metric equivalents see table below.
36
(11,0) 50° D
13.00 R 24 ONE STAR RADIALS This rating specifies the maximum load capacity that the
at 80 psi (551 kPa)
32 C
(9,8)
40° 15.5 – 25 12 PLY TIRES
individual fork can safely carry at a maximum load
B at 58 psi (400 kPa)
28
(8,5) 8000 LBS center of 24" (610 mm) (See Figure 19). Since forks are
3630 KG 17.5 – 25 12 PLY TIRES
24
A at 51 psi (352 kPa) always used in multiples, the total load rating of any
(7,3) 30°
6000 LBS Hydrofill per operators manual combination of forks will be the sum of their rated
2720 KG
20
(6,1) Load Ratings per capacities.
ASME B56.6b-1998
20° 4000 LBS
16
(4,9) 1810 KG
INDIVIDUAL FORK RATING EQUIVALENTS
12
(3,7) 3000 LBS
1360 KG 24 INCH LOAD CENTER 610 MM LOAD CENTER
10°
8
(2,4)
2500 LBS 1900 lbs. .................................... 860 kg
1130 KG LOAD CENTER
4
(1,2) 3000 lbs. .................................... 1360 kg
0° 24 in (610 mm)
0 FT
1800 LBS 4000 lbs. .................................... 1810 kg
(0 M)
820 KG
5000 lbs. .................................... 2270 kg
-4
-(1,2)
27 21 19 16 12 9.5
(8,2) (6,4) (5,8) (4,9) (3,7) (2,9)

OH1111

Page 42 8042 Rev 3/04

Fork Ratings
All forks that can be used on this vehicle are marked
SIDE TILT CARRIAGE with a maximum load capacity rating. This rating can
ATTACHMENT ON be found stamped on the left edge of the fork just below
8042
28 24 20 16 12 8 4 0 FT
(8,5) (7,3) (6,1) (4,9) (3,7) (2,4) (1,2) (0 M)
44
(13,4)
the fork pivot shaft (See Figure 19). This rating is listed
40 60° in U.S. pounds and based upon a 24" (610 mm) load
(12,2) E 13.00 – 24 12 PLY TIRES
at 70 psi (482 kPa)
center. For metric equivalents see table below.
36
(11,0) 50° D
13.00 R 24 ONE STAR RADIALS This rating specifies the maximum load capacity that the
at 80 psi (551 kPa)
32 C
(9,8)
40° 15.5 – 25 12 PLY TIRES
individual fork can safely carry at a maximum load
B at 58 psi (400 kPa)
28
(8,5) 8000 LBS center of 24" (610 mm) (See Figure 19). Since forks are
3630 KG 17.5 – 25 12 PLY TIRES
24
A at 51 psi (352 kPa) always used in multiples, the total load rating of any
(7,3) 30°
6000 LBS Hydrofill per operators manual combination of forks will be the sum of their rated
2720 KG
20
(6,1) Load Ratings per capacities.
ASME B56.6b-1998
20° 4000 LBS
16
(4,9) 1810 KG
INDIVIDUAL FORK RATING EQUIVALENTS
12
(3,7) 3000 LBS
1360 KG 24 INCH LOAD CENTER 610 MM LOAD CENTER
10°
8
(2,4)
2500 LBS 1900 lbs. .................................... 860 kg
1130 KG LOAD CENTER
4
(1,2) 3000 lbs. .................................... 1360 kg
0° 24 in (610 mm)
0 FT
1800 LBS 4000 lbs. .................................... 1810 kg
(0 M)
820 KG
5000 lbs. .................................... 2270 kg
-4
-(1,2)
27 21 19 16 12 9.5
(8,2) (6,4) (5,8) (4,9) (3,7) (2,9)

OH1111

Page 42 8042 Rev 3/04

 The maximum load capacity for the model 8042 is 8000
lbs (3630 kg). Forks used on this vehicle should have LOCATION
STAMPED FORK
total load ratings which equal or exceed 8000 lbs RATING
(3630 kg). When the load rating of the vehicle differs
from the load capacity rating of the forks, the lower value MAXIMUM
24" LOAD
becomes the overall load capacity. See WARNING this
CENTER

3000 x 24
page.

3000 x 24
WARNING
DO NOT exceed the total rated load capacity of the
specific type fork being used. Forks can break
causing loss of load and possible death or serious
injury to the operator or other personnel in the area. Figure 19 OA1061

If the total rated load capacity of the forks exceeds

the capacity of the vehicle, the vehicle capacity
governs.

8042 Rev 3/04 Page 43

The maximum load capacity for the model 8042 is 8000

lbs (3630 kg). Forks used on this vehicle should have LOCATION
STAMPED FORK
total load ratings which equal or exceed 8000 lbs RATING
(3630 kg). When the load rating of the vehicle differs
from the load capacity rating of the forks, the lower value MAXIMUM
24" LOAD
becomes the overall load capacity. See WARNING this
CENTER
3000 x 24

page.
3000 x 24

WARNING
DO NOT exceed the total rated load capacity of the
specific type fork being used. Forks can break
causing loss of load and possible death or serious
injury to the operator or other personnel in the area. Figure 19 OA1061

If the total rated load capacity of the forks exceeds

the capacity of the vehicle, the vehicle capacity
governs.

8042 Rev 3/04 Page 43

 How To Pick, Carry & Place A Load Elevating Personnel
To pick up a load, tilt carriage forward so that forks hang If this vehicle must be used to elevate personnel, use only
freely on the fork shaft. Move the forks inward or outward an approved work platform. When using a work platform,
on the fork shaft so that they are aligned with the openings the following precautions must be taken:
in the pallet. Tilt the carriage back and extend the boom
slowly so that the forks slide into the openings in the
pallet. Raise the boom so that the load is lifted. WARNING
To carry a load, position the boom so that the load is as Use an approved work platform to lift or lower person-
low as possible and the travel area is visible to the opera- nel. NEVER move the vehicle with the work platform
tor. in a raised position or with personnel on board.
Then use the capacity chart to determine safe boom Preparation and Setup
extension range for the applicable load. To place a load, 1. Make sure that the work platform is securely
align the forks at the level the load is to be placed and then attached to the quick attach or forks. Follow the
extend the boom slowly until the load is just above the platform manufacturer’s instructions.
area where it is to be placed. Lower the boom until the
pallet rests in position and the forks are free to retract. 2. Make sure that the platform, carriage and forks are
Retract the forks slowly from under the load. secured 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
move neutral lock lever to NEUTRAL LOCK position.
5. Engage the emergency brake switch. Blocking of
the vehicle wheels is also recommended.
6. Level the platform in both the side to side and front
to back directions before use.
Page 44 8042 Rev 3/04

How To Pick, Carry & Place A Load Elevating Personnel

To pick up a load, tilt carriage forward so that forks hang If this vehicle must be used to elevate personnel, use only
freely on the fork shaft. Move the forks inward or outward an approved work platform. When using a work platform,
on the fork shaft so that they are aligned with the openings the following precautions must be taken:
in the pallet. Tilt the carriage back and extend the boom
slowly so that the forks slide into the openings in the
pallet. Raise the boom so that the load is lifted. WARNING
To carry a load, position the boom so that the load is as Use an approved work platform to lift or lower person-
low as possible and the travel area is visible to the opera- nel. NEVER move the vehicle with the work platform
tor. in a raised position or with personnel on board.
Then use the capacity chart to determine safe boom Preparation and Setup
extension range for the applicable load. To place a load, 1. Make sure that the work platform is securely
align the forks at the level the load is to be placed and then attached to the quick attach or forks. Follow the
extend the boom slowly until the load is just above the platform manufacturer’s instructions.
area where it is to be placed. Lower the boom until the
pallet rests in position and the forks are free to retract. 2. Make sure that the platform, carriage and forks are
Retract the forks slowly from under the load. secured 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
move neutral lock lever to NEUTRAL LOCK position.
5. Engage the emergency brake switch. Blocking of
the vehicle wheels is also recommended.
6. Level the platform in both the side to side and front
to back directions before use.
Page 44 8042 Rev 3/04
Lifting Personnel 3. Always lower the platform to the travel position
(approximately one foot above ground level) before
moving the vehicle.
WARNING IMPORTANT: Make sure that required restraining means
such as railings, chains, cable, body belts with lanyards,
NEVER tilt platform forward or rearward when
etc. are in place and properly used. Never use railings,
elevated with personnel aboard. Serious injury or
planks, ladders, etc. on the platform for the purpose of
death could result.
achieving additional reach or height.
In case of engine failure and subsequent loss of power for
DANGER controls, refer to emergency boom lowering procedure (under
General Maintenance in this manual).
NEVER operate this or any equipment in an area in
which overhead power lines, overhead or under- Capacity Limitation
ground cables, or power sources exist without first
requesting that the appropriate power company or The combined mass (weight in pounds) of the platform, load
utility company de-energize the lines or take other and personnel shall not exceed one-third of the capacity of
suitable precautions. the related load center position indicated on the capacity
chart, located on the right side wall of the operator’s
1. Make sure there are no overhead obstructions compartment. Refer also to “Using the Capacity Chart.”
or electrical wires above platform before lifting.
2. A trained telescopic handler operator must operate
the controls from the operator's compartment.
Using extreme caution, lift and lower personnel
smoothly and only at their request. The operator
should always alert personnel on the platform and in
the work area before moving it up or down.

8042 Rev 3/04 Page 45

Lifting Personnel 3. Always lower the platform to the travel position

(approximately one foot above ground level) before
moving the vehicle.
WARNING IMPORTANT: Make sure that required restraining means
such as railings, chains, cable, body belts with lanyards,
NEVER tilt platform forward or rearward when
etc. are in place and properly used. Never use railings,
elevated with personnel aboard. Serious injury or
planks, ladders, etc. on the platform for the purpose of
death could result.
achieving additional reach or height.
In case of engine failure and subsequent loss of power for
DANGER controls, refer to emergency boom lowering procedure (under
General Maintenance in this manual).
NEVER operate this or any equipment in an area in
which overhead power lines, overhead or under- Capacity Limitation
ground cables, or power sources exist without first
requesting that the appropriate power company or The combined mass (weight in pounds) of the platform, load
utility company de-energize the lines or take other and personnel shall not exceed one-third of the capacity of
suitable precautions. the related load center position indicated on the capacity
chart, located on the right side wall of the operator’s
1. Make sure there are no overhead obstructions compartment. Refer also to “Using the Capacity Chart.”
or electrical wires above platform before lifting.
2. A trained telescopic handler operator must operate
the controls from the operator's compartment.
Using extreme caution, lift and lower personnel
smoothly and only at their request. The operator
should always alert personnel on the platform and in
the work area before moving it up or down.

8042 Rev 3/04 Page 45

 Following is a list of some of the attachments that are
Using Other Attachments available through JLG for this vehicle model:
Numerous attachments, some marketed by JLG and some 48", 60" and 72" Carriage
sold by third party sources, are available for this vehicle. 1-1/4 Cubic Yard Bucket
The general rule is that any attachment used on this
Auger Unit with Drive and Extensions
vehicle must be intended for the function of lifting only.
This vehicle is not designed to PULL, TOW or DRAG other Windrow Broom
objects. DO NOT use attachments that perform these The standard capacity chart for this vehicle (Figure 18) is
functions with this vehicle. applicable for all of the above listed attachments. The
attachments listed below are supplied with their own
Some JLG attachments are supplied with a capacity chart capacity charts.
that is to be affixed to the vehicle near the original capacity
48", 60" and 72" Sidetilt Carriage
chart (Figure 20 - #4) for operator reference. Third party
sources may or may not supply capacity charts with their 52" and 72" Swing Carriage
attachments. Capacity ratings for these type attachments 12' Truss Boom
should be obtained from the third party source.
Hydraulically actuated attachments also have a maximum
JLG makes no representations or warranties, express or hydraulic pressure rating. Make sure that the maximum
implied, as to the design, manufacture or fitness for use hydraulic pressure of the attachment is equal to or slightly
with this vehicle of any third party source attachments. greater than 3000 psi, which is the maximum hydraulic
This vehicle is not intended to be used and should not be pressure of this vehicles auxiliary hydraulics.
used with any attachment that would alter the center of
gravity stability of this vehicle. JLG assumes no liability IMPORTANT: If the maximum pressure of the vehicle
for any third party attachment that would alter the center of exceeds the pressure rating of the attachment, the
gravity stability. attachment’s hydraulic components could burst. If the
maximum pressure of the vehicle is much lower than the
pressure rating of the attachment, the attachment may
not work properly.

Page 46 8042 Rev 3/04

Following is a list of some of the attachments that are

Using Other Attachments available through JLG for this vehicle model:
Numerous attachments, some marketed by JLG and some 48", 60" and 72" Carriage
sold by third party sources, are available for this vehicle. 1-1/4 Cubic Yard Bucket
The general rule is that any attachment used on this
Auger Unit with Drive and Extensions
vehicle must be intended for the function of lifting only.
This vehicle is not designed to PULL, TOW or DRAG other Windrow Broom
objects. DO NOT use attachments that perform these The standard capacity chart for this vehicle (Figure 18) is
functions with this vehicle. applicable for all of the above listed attachments. The
attachments listed below are supplied with their own
Some JLG attachments are supplied with a capacity chart capacity charts.
that is to be affixed to the vehicle near the original capacity
48", 60" and 72" Sidetilt Carriage
chart (Figure 20 - #4) for operator reference. Third party
sources may or may not supply capacity charts with their 52" and 72" Swing Carriage
attachments. Capacity ratings for these type attachments 12' Truss Boom
should be obtained from the third party source.
Hydraulically actuated attachments also have a maximum
JLG makes no representations or warranties, express or hydraulic pressure rating. Make sure that the maximum
implied, as to the design, manufacture or fitness for use hydraulic pressure of the attachment is equal to or slightly
with this vehicle of any third party source attachments. greater than 3000 psi, which is the maximum hydraulic
This vehicle is not intended to be used and should not be pressure of this vehicles auxiliary hydraulics.
used with any attachment that would alter the center of
gravity stability of this vehicle. JLG assumes no liability IMPORTANT: If the maximum pressure of the vehicle
for any third party attachment that would alter the center of exceeds the pressure rating of the attachment, the
gravity stability. attachment’s hydraulic components could burst. If the
maximum pressure of the vehicle is much lower than the
pressure rating of the attachment, the attachment may
not work properly.

Page 46 8042 Rev 3/04

 Shut-Off Towing and Tie Down
1. Park the vehicle on level ground. If the vehicle becomes disabled and cannot be moved
under engine power, the vehicle can be towed a short

WARNING distance (50 to 100 feet) by another piece of equipment,

which is designed for towing. However, when considering
towing the vehicle longer distances (such as site to site),
To prevent personal injury or death, be certain to lower
the vehicle should be loaded onto a trailer for transport.
the boom, shut off the engine, and engage the emer-
gency brake switch before exiting the vehicle. Short Distance Towing —
Short distance towing should only be attempted when
2. Place travel select lever in (N) NEUTRAL, move
the vehicle becomes disabled and would create a
the neutral lock lever to NEUTRAL LOCK position
potentially hazardous situation such as on a roadway or
and engage the emergency brake switch.
in an unsafe area on the work site. Prepare the vehicle
3. Lower the boom and ground the carriage. for towing as follows:
4. Turn ignition key to OFF position and remove key. • Detach the front and rear drive shafts from the
axles.
• Tie the drive shafts up to the vehicle.

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

IMPORTANT: Without engine power, the vehicle will not
have service brakes for stopping. Steering will also be
extremely difficult. Tow or push the vehicle at a very
slow speed!
Tie Down —
This vehicle is equipped with tie down holes in the
frame on the front and rear ends for transport tie down.

8042 Rev 3/04 Page 47

Shut-Off Towing and Tie Down

1. Park the vehicle on level ground. If the vehicle becomes disabled and cannot be moved
under engine power, the vehicle can be towed a short

WARNING distance (50 to 100 feet) by another piece of equipment,

which is designed for towing. However, when considering
towing the vehicle longer distances (such as site to site),
To prevent personal injury or death, be certain to lower
the vehicle should be loaded onto a trailer for transport.
the boom, shut off the engine, and engage the emer-
gency brake switch before exiting the vehicle. Short Distance Towing —
Short distance towing should only be attempted when
2. Place travel select lever in (N) NEUTRAL, move
the vehicle becomes disabled and would create a
the neutral lock lever to NEUTRAL LOCK position
potentially hazardous situation such as on a roadway or
and engage the emergency brake switch.
in an unsafe area on the work site. Prepare the vehicle
3. Lower the boom and ground the carriage. for towing as follows:
4. Turn ignition key to OFF position and remove key. • Detach the front and rear drive shafts from the
axles.
• Tie the drive shafts up to the vehicle.

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

IMPORTANT: Without engine power, the vehicle will not
have service brakes for stopping. Steering will also be
extremely difficult. Tow or push the vehicle at a very
slow speed!
Tie Down —
This vehicle is equipped with tie down holes in the
frame on the front and rear ends for transport tie down.

8042 Rev 3/04 Page 47

General Maintenance Routine Equipment Checklist
Inspect the following equipment daily:
This section of the manual contains a routine equipment Safety Belt
checklist and a maintenance schedule and checklist with Check for frayed or cut webbing, damaged buckles, or
references to pertinent procedures and instructions. To loose mounting brackets.
prevent problems before they occur, follow the schedule. Safety Surfaces
Keep all non-skid surfaces clean. Replace safety
NOTE: The Lubrication and Maintenance Decal found treads if worn, damaged or missing.
inside the right rear engine door contains a general Warning Decals
maintenance schedule that should be followed to
Check condition of all decals (Figure 20). Replace if
maintain this vehicle in good operating condition. The missing, damaged or illegible.
same schedule is presented in this manual, except it
Covers
contains a more detailed account of how to perform
these specific maintenance operations. Keep all protective covers in place.
Emergency Brake
Check operation. Have unit repaired immediately if
required.
Quick Attach
WARNING Make sure that the quick attach pin secures the
attachment and that the release lever is seated in the
DO NOT perform service or maintenance on the pin groove.
vehicle with the engine running. Contact with moving Engine
parts can cause serious injury or death. Check cleanliness. Remove all dirt or debris, and all
flammable materials before running engine.
Tires
Check tire pressure and hydrofill. Add air and/or
hydrofill if required per “Specifications.”

Page 48 8042 Rev 3/04

General Maintenance Routine Equipment Checklist

Inspect the following equipment daily:
This section of the manual contains a routine equipment Safety Belt
checklist and a maintenance schedule and checklist with Check for frayed or cut webbing, damaged buckles, or
references to pertinent procedures and instructions. To loose mounting brackets.
prevent problems before they occur, follow the schedule. Safety Surfaces
Keep all non-skid surfaces clean. Replace safety
NOTE: The Lubrication and Maintenance Decal found treads if worn, damaged or missing.
inside the right rear engine door contains a general Warning Decals
maintenance schedule that should be followed to
Check condition of all decals (Figure 20). Replace if
maintain this vehicle in good operating condition. The missing, damaged or illegible.
same schedule is presented in this manual, except it
Covers
contains a more detailed account of how to perform
these specific maintenance operations. Keep all protective covers in place.
Emergency Brake
Check operation. Have unit repaired immediately if
required.
Quick Attach
WARNING Make sure that the quick attach pin secures the
attachment and that the release lever is seated in the
DO NOT perform service or maintenance on the pin groove.
vehicle with the engine running. Contact with moving Engine
parts can cause serious injury or death. Check cleanliness. Remove all dirt or debris, and all
flammable materials before running engine.
Tires
Check tire pressure and hydrofill. Add air and/or
hydrofill if required per “Specifications.”

Page 48 8042 Rev 3/04

 2 3 4
1
A B C
4105262

8 9

7
•
•

- + •

10 11 5 6 7

Warning Decal Locations

1. CARRYING PERSONNEL LEFT CONSOLE OVERLAY
WARNING 8. MACHINE ROLLAWAY
2. BOOM EXTEND LETTERS WARNING
3. BOOM ANGLE INDICATOR 9. SAFETY INSTRUCTIONS
4. CAPACITY CHART
5. EXPLOSIVE GASES WARNING RIGHT CONSOLE OVERLAY
6. STABILIZER TIPOVER DANGER 10. TIPOVER DANGER
7. MOVING PARTS WARNING 11. ELECTROCUTION
DANGER
Figure 20 OH0102

8042 Rev 3/04 Page 49

2 3 4
1
A B C
4105262

8 9

7
•
•

- + •

10 11 5 6 7

Warning Decal Locations

1. CARRYING PERSONNEL LEFT CONSOLE OVERLAY
WARNING 8. MACHINE ROLLAWAY
2. BOOM EXTEND LETTERS WARNING
3. BOOM ANGLE INDICATOR 9. SAFETY INSTRUCTIONS
4. CAPACITY CHART
5. EXPLOSIVE GASES WARNING RIGHT CONSOLE OVERLAY
6. STABILIZER TIPOVER DANGER 10. TIPOVER DANGER
7. MOVING PARTS WARNING 11. ELECTROCUTION
DANGER
Figure 20 OH0102

8042 Rev 3/04 Page 49

 Maintenance Schedule and Checklist

Daily or 10 Hour Intervals

Reference
Check Change Clean Paragraph
Air Cleaner Restriction Indicator (Air Filter Elements) X 2A
Air Cleaner Vacuator Valve X 2A
Engine Coolant Level X 3A
Engine Oil Level X 4A
Hydraulic Oil Level and Leaks in System X 7B
Tire Pressure/Hydrofill and Wear X 11A & B
Drain Fuel Water Separator X 5C
Transmission Oil Level X 8A

At First 50 Hours of Use

Reference
Check Change Clean Paragraph
Hydraulic Oil Filter X 7C
Wheel Lug Nuts X 11C
Boom Chain Tension X 14A
Transmission Oil X 8C
Transmission Filter X 8B

Page 50 8042 Rev 3/04

Maintenance Schedule and Checklist

Daily or 10 Hour Intervals

Reference
Check Change Clean Paragraph
Air Cleaner Restriction Indicator (Air Filter Elements) X 2A
Air Cleaner Vacuator Valve X 2A
Engine Coolant Level X 3A
Engine Oil Level X 4A
Hydraulic Oil Level and Leaks in System X 7B
Tire Pressure/Hydrofill and Wear X 11A & B
Drain Fuel Water Separator X 5C
Transmission Oil Level X 8A

At First 50 Hours of Use

Reference
Check Change Clean Paragraph
Hydraulic Oil Filter X 7C
Wheel Lug Nuts X 11C
Boom Chain Tension X 14A
Transmission Oil X 8C
Transmission Filter X 8B

Page 50 8042 Rev 3/04

 50 Hour Intervals
Reference
Check Change Lube Paragraph
Boom Wear Pads X 14D
Carriage Pivot Pin X 1
Fork Tilt Cylinder Pins X 1
Boom Attachments X 1
Extend Chain Sheave Pin X 1
Emergency Brake Test X 16

250 Hour Intervals

Reference
Check Change Lube Paragraph
Boom Wear Pads X 14D
Axle Oil Level X 9A
Wheel End Oil X 10
Air Intake Hoses X 2C
Hydraulic Cylinder Pins X 1
Drive Shaft Slip Joints X 1
Boom Pivot Pin X 1
Carriage Pivot Pin X 1
Fork Tilt Cylinder Pins X 1
Axle Pivot Pins X 1
Extend Chain Sheave Pin X 1

continued on next page

8042 Rev 3/04 Page 51

50 Hour Intervals
Reference
Check Change Lube Paragraph
Boom Wear Pads X 14D
Carriage Pivot Pin X 1
Fork Tilt Cylinder Pins X 1
Boom Attachments X 1
Extend Chain Sheave Pin X 1
Emergency Brake Test X 16

250 Hour Intervals

Reference
Check Change Lube Paragraph
Boom Wear Pads X 14D
Axle Oil Level X 9A
Wheel End Oil X 10
Air Intake Hoses X 2C
Hydraulic Cylinder Pins X 1
Drive Shaft Slip Joints X 1
Boom Pivot Pin X 1
Carriage Pivot Pin X 1
Fork Tilt Cylinder Pins X 1
Axle Pivot Pins X 1
Extend Chain Sheave Pin X 1

continued on next page

8042 Rev 3/04 Page 51

 250 Hour Intervals (continued)
Reference
Check Change Lube Paragraph
Axle Steer Knuckles X 1
Axle Tie Rod Ball Joints X 1
Axle Steer Cylinder Ball Joints X 1
Boom Attachments X 1
Engine Oil and Filter X 4B
Drain or Change Fuel Filters X 5C

1,000 Hours or Annually

Reference
Check Change Lube Paragraph
Boom Wear Pads X 14D
Air Intake Hoses X 2C
Fan Belt Wear X 6
Boom Chain Tension X 14A
Hydraulic Cylinder Pins X 1
Drive Shaft Slip Joints X 1
Boom Pivot Pin X 1
Carriage Pivot Pin X 1
Fork Tilt Cylinder Pins X 1

continued on next page

Page 52 8042 Rev 3/04

250 Hour Intervals (continued)

Reference
Check Change Lube Paragraph
Axle Steer Knuckles X 1
Axle Tie Rod Ball Joints X 1
Axle Steer Cylinder Ball Joints X 1
Boom Attachments X 1
Engine Oil and Filter X 4B
Drain or Change Fuel Filters X 5C

1,000 Hours or Annually

Reference
Check Change Lube Paragraph
Boom Wear Pads X 14D
Air Intake Hoses X 2C
Fan Belt Wear X 6
Boom Chain Tension X 14A
Hydraulic Cylinder Pins X 1
Drive Shaft Slip Joints X 1
Boom Pivot Pin X 1
Carriage Pivot Pin X 1
Fork Tilt Cylinder Pins X 1

continued on next page

Page 52 8042 Rev 3/04

 1,000 Hours or Annually (continued)
Reference
Check Change Lube Paragraph
Extend Chain Sheave Pin X 1
Axle Pivot Pins X 1
Axle Steer Knuckles X 1
Axle Tie Rod Ball Joints X 1
Axle Steer Cylinder Ball Joints X 1
Boom Attachments X 1
Extend Chains X 14C
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 2B
Hydraulic Oil and Filter X 7C
Engine Coolant X 3B
Fuel Pre-Filter X 5C

8042 Rev 3/04 Page 53

1,000 Hours or Annually (continued)

Reference
Check Change Lube Paragraph
Extend Chain Sheave Pin X 1
Axle Pivot Pins X 1
Axle Steer Knuckles X 1
Axle Tie Rod Ball Joints X 1
Axle Steer Cylinder Ball Joints X 1
Boom Attachments X 1
Extend Chains X 14C
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 2B
Hydraulic Oil and Filter X 7C
Engine Coolant X 3B
Fuel Pre-Filter X 5C

8042 Rev 3/04 Page 53

 1. Lubrication Points H
I
Lubricate the following grease fittings using Multi-Purpose
Grease (MPG) every 50 hour interval (Figure 21): K
A. Carriage pivot pin ...................... (2 points)
B. Fork tilt cylinder pins .................. (2 points)
C. Boom attachments ................... (All points)
D. Extend Chain Sheave Pin ............ (1 point)

I
E G
D Figure 22 OA0192

B Lubricate the following grease fittings using Multi-Purpose

C Grease (MPG) every 250 hour interval (Figures 21 & 22):
E. Hydraulic cylinder pins............. (12 points)
E F. Drive shaft slip joints.................. (3 points)
A G. Boom pivot pin ........................... (2 points)
B H. Axle pivot pins ........................... (2 points)
I. Axle steer knuckles ................... (8 points)
E J. Axle tie rod ball joints ................. (4 points)
K. Axle steer cylinder ball joints ..... (8 points)
F NOTE: Shorten the lubrication interval on all axle and drive
shaft lube points, and lower tilt, hoist, and stabilizer cylinder
Figure 21 OH1170
pins when operating in wet or muddy conditions.

Page 54 8042 Rev 3/04

1. Lubrication Points H
I
Lubricate the following grease fittings using Multi-Purpose
Grease (MPG) every 50 hour interval (Figure 21): K
A. Carriage pivot pin ...................... (2 points)
B. Fork tilt cylinder pins .................. (2 points)
C. Boom attachments ................... (All points)
D. Extend Chain Sheave Pin ............ (1 point)

I
E G
D Figure 22 OA0192

B Lubricate the following grease fittings using Multi-Purpose

C Grease (MPG) every 250 hour interval (Figures 21 & 22):
E. Hydraulic cylinder pins............. (12 points)
E F. Drive shaft slip joints.................. (3 points)
A G. Boom pivot pin ........................... (2 points)
B H. Axle pivot pins ........................... (2 points)
I. Axle steer knuckles ................... (8 points)
E J. Axle tie rod ball joints ................. (4 points)
K. Axle steer cylinder ball joints ..... (8 points)
F NOTE: Shorten the lubrication interval on all axle and drive
shaft lube points, and lower tilt, hoist, and stabilizer cylinder
Figure 21 OH1170
pins when operating in wet or muddy conditions.

Page 54 8042 Rev 3/04

 2. Air Cleaner & Restriction Indicator

RESTRICTION INDICATOR
AIR CLEANER
INDICATOR WINDOW

VACUATOR VALVE

OA0212
Figure 24

OA0203
NOTE: Depress button on top of indicator to reset
Figure 23 indicator after servicing element.
A. Filter Check (Daily or 10 Hour Intervals) IMPORTANT: Only remove canister cover to service
1. Ground the carriage, place the travel select lever the elements as restriction indicator indicates or
in (N) NEUTRAL, place the neutral lock lever to during scheduled maintenance intervals. Excessive
NEUTRAL LOCK position, engage the emergency access to check or clean an element can lead to
brake switch and shut off the engine. premature element failure and increase the possibility
of dirt entering the engine.
2. Unlock and open the left rear engine access door
to access air cleaner restriction indicator (Figure 3. Remove dust from vacuator valve (Figure 24) by
23). Check indicator. If red band has appeared, squeezing bottom of vacuator to allow loose
filter must be cleaned or replaced. particles to fall out. Replace elements, if required,
as described in paragraph 2B.

8042 Rev 3/04 Page 55

2. Air Cleaner & Restriction Indicator

RESTRICTION INDICATOR
AIR CLEANER
INDICATOR WINDOW

VACUATOR VALVE

OA0212
Figure 24

OA0203
NOTE: Depress button on top of indicator to reset
Figure 23 indicator after servicing element.
A. Filter Check (Daily or 10 Hour Intervals) IMPORTANT: Only remove canister cover to service
1. Ground the carriage, place the travel select lever the elements as restriction indicator indicates or
in (N) NEUTRAL, place the neutral lock lever to during scheduled maintenance intervals. Excessive
NEUTRAL LOCK position, engage the emergency access to check or clean an element can lead to
brake switch and shut off the engine. premature element failure and increase the possibility
of dirt entering the engine.
2. Unlock and open the left rear engine access door
to access air cleaner restriction indicator (Figure 3. Remove dust from vacuator valve (Figure 24) by
23). Check indicator. If red band has appeared, squeezing bottom of vacuator to allow loose
filter must be cleaned or replaced. particles to fall out. Replace elements, if required,
as described in paragraph 2B.

8042 Rev 3/04 Page 55

 Careful cleaning or washing, if done correctly, can
CANNISTER extend the life of an element. But you must realize that
each time an element is cleaned the dirt holding
PRIMARY ELEMENT capacity is reduced and the risk of dirt reaching the
clean side of the filter is increased. Filters should
never be washed more than six times or retained for
more than one year’s service, whichever comes first.

WING NUT
If you wash an element, it is recommended that you
use a non-sudsing detergent that dissolves combustion
residues without damaging the filter media. One such
COVER WITH
WING NUT
detergent that is specifically formulated for this pur-
pose is FM 1400. This cleaner contains biodegradable
synthetic detergents and is environmentally safe. It is
marketed by Filter Service Corp., 2105 W. Apache,
Figure 25 OF0110
Farmington, New Mexico, 87401, Telephone (505)
B. Element: Change or Clean 326-1127.
(As Restriction Indicator Indicates
or Every 1000 Hour Interval) Inner Safety Element
Outer Primary Element An inner safety element should never be washed or
reused. Always install a new element. Replace safety
All air cleaner manufacturers agree that attempting to
elements after every third primary element change.
clean or wash an element increases the chance for
DO NOT remove a safety element until you have
element damage. It is highly recommended that you
thoroughly cleaned the inside of the air cleaner canis-
consider the value of cleaning an element against the
ter. This will prevent dirt, which could damage the
risks which could lead to engine damage. Adopt the
engine, from entering the induction manifold.
policy that all elements should be replaced with new
and not cleaned.

Page 56 8042 Rev 3/04

Careful cleaning or washing, if done correctly, can

CANNISTER extend the life of an element. But you must realize that
each time an element is cleaned the dirt holding
PRIMARY ELEMENT capacity is reduced and the risk of dirt reaching the
clean side of the filter is increased. Filters should
never be washed more than six times or retained for
more than one year’s service, whichever comes first.

WING NUT
If you wash an element, it is recommended that you
use a non-sudsing detergent that dissolves combustion
residues without damaging the filter media. One such
COVER WITH
WING NUT
detergent that is specifically formulated for this pur-
pose is FM 1400. This cleaner contains biodegradable
synthetic detergents and is environmentally safe. It is
marketed by Filter Service Corp., 2105 W. Apache,
Figure 25 OF0110
Farmington, New Mexico, 87401, Telephone (505)
B. Element: Change or Clean 326-1127.
(As Restriction Indicator Indicates
or Every 1000 Hour Interval) Inner Safety Element
Outer Primary Element An inner safety element should never be washed or
reused. Always install a new element. Replace safety
All air cleaner manufacturers agree that attempting to
elements after every third primary element change.
clean or wash an element increases the chance for
DO NOT remove a safety element until you have
element damage. It is highly recommended that you
thoroughly cleaned the inside of the air cleaner canis-
consider the value of cleaning an element against the
ter. This will prevent dirt, which could damage the
risks which could lead to engine damage. Adopt the
engine, from entering the induction manifold.
policy that all elements should be replaced with new
and not cleaned.

Page 56 8042 Rev 3/04

 To change elements:

1. Loosen cover wing nut and remove cover from air WING NUT
cleaner canister (Figure 25).
SAFETY ELEMENT
2. Remove wing nut and primary element. Inspect
element for damage. Damaged elements should
not be cleaned or reused.
3. Thoroughly clean the interior of the air filter
canister and vacuator valve.
4. If replacing safety element at this time (Figure 26),
remove wing nut and carefully slide safety ele- Figure 26 OF0120

ment out. Always discard this element and

replace with a new element and secure with wing 2. Soak filter in a non-sudsing detergent (such as FM
nut. 1400) for at least 15 minutes. Never soak more
than 24 hours.
5. Install the new primary element and secure with
wing nut. 3. Swish filter around in the solution to remove
loosened dirt particles.
6. Position canister cover in place and secure with
cover wing nut. 4. Rinse the filter from the inside out with a gentle
Carefully follow these procedures to clean an element: stream of water to remove all dirt and suds (less
1. Remove loose particles from the filter with com- than 40 psi [275 kPa], no nozzle). If the inside of
pressed air (maximum 30 psi [206 kPa]) or water the element has been contaminated with dirty
hose (maximum 40 psi [275 kPa] without nozzle). water from the soaking, rinse from both sides.
Rotate and apply pressure from the inside of the 5. Dry the filter before re-using. Circulate warm air
element. at less than 160° F (71° C). DO NOT use a light
bulb to dry the filter.

8042 Rev 3/04 Page 57

To change elements:

1. Loosen cover wing nut and remove cover from air WING NUT
cleaner canister (Figure 25).
SAFETY ELEMENT
2. Remove wing nut and primary element. Inspect
element for damage. Damaged elements should
not be cleaned or reused.
3. Thoroughly clean the interior of the air filter
canister and vacuator valve.
4. If replacing safety element at this time (Figure 26),
remove wing nut and carefully slide safety ele- Figure 26 OF0120

ment out. Always discard this element and

replace with a new element and secure with wing 2. Soak filter in a non-sudsing detergent (such as FM
nut. 1400) for at least 15 minutes. Never soak more
than 24 hours.
5. Install the new primary element and secure with
wing nut. 3. Swish filter around in the solution to remove
loosened dirt particles.
6. Position canister cover in place and secure with
cover wing nut. 4. Rinse the filter from the inside out with a gentle
Carefully follow these procedures to clean an element: stream of water to remove all dirt and suds (less
1. Remove loose particles from the filter with com- than 40 psi [275 kPa], no nozzle). If the inside of
pressed air (maximum 30 psi [206 kPa]) or water the element has been contaminated with dirty
hose (maximum 40 psi [275 kPa] without nozzle). water from the soaking, rinse from both sides.
Rotate and apply pressure from the inside of the 5. Dry the filter before re-using. Circulate warm air
element. at less than 160° F (71° C). DO NOT use a light
bulb to dry the filter.

8042 Rev 3/04 Page 57

 6. Inspect for holes or tears by looking through the
filter toward a bright light. Check for damaged
gaskets or metal parts. DO NOT re-use damaged
filters.
C. Air Intake System - Inspection (250 Hour Intervals)
Inspect the intake piping for cracked hoses, loose
clamps, or punctures which can allow dirt or debris to
enter the combustion chamber. If dirt or debris is
allowed to enter the combustion chamber, it can
severely damage the engine. If necessary tighten or
replace parts to prevent air intake system leakage.

3. Engine Cooling System

COOLANT OIL FILL
OIL
A. Level Check (Daily or 10 Hour Intervals) OVERFLOW CAP
DIPSTICK
BOTTLE
1. Level the vehicle, ground the carriage, place the
Figure 27 MA2021
travel select lever in (N) NEUTRAL, move the
neutral lock lever to NEUTRAL LOCK position,
engage the emergency brake switch and shut off 2. Unlock and open the right rear engine access
the engine. door. Check level of coolant in overflow bottle
(Figure 27). When coolant is hot, bottle should be
1/2 to 3/4 full. When coolant is cool, bottle should
be 1/4 to 1/2 full. Add coolant as required through
the overflow bottle (50/50 mixture of ethylene
glycol and water). Close and lock access door.

Page 58 8042 Rev 3/04

6. Inspect for holes or tears by looking through the

filter toward a bright light. Check for damaged
gaskets or metal parts. DO NOT re-use damaged
filters.
C. Air Intake System - Inspection (250 Hour Intervals)
Inspect the intake piping for cracked hoses, loose
clamps, or punctures which can allow dirt or debris to
enter the combustion chamber. If dirt or debris is
allowed to enter the combustion chamber, it can
severely damage the engine. If necessary tighten or
replace parts to prevent air intake system leakage.

3. Engine Cooling System

COOLANT OIL FILL
OIL
A. Level Check (Daily or 10 Hour Intervals) OVERFLOW CAP
DIPSTICK
BOTTLE
1. Level the vehicle, ground the carriage, place the
Figure 27 MA2021
travel select lever in (N) NEUTRAL, move the
neutral lock lever to NEUTRAL LOCK position,
engage the emergency brake switch and shut off 2. Unlock and open the right rear engine access
the engine. door. Check level of coolant in overflow bottle
(Figure 27). When coolant is hot, bottle should be
1/2 to 3/4 full. When coolant is cool, bottle should
be 1/4 to 1/2 full. Add coolant as required through
the overflow bottle (50/50 mixture of ethylene
glycol and water). Close and lock access door.

Page 58 8042 Rev 3/04

B. Drain and Flush Radiator (1000 Hours or Annually) 1. Open rear radiator door. Remove radiator cap and
open petcock at bottom center of radiator (Figure
28).
WARNING NOTE: Attach a hose to the petcock to allow draining
directly into a container.
NEVER remove the radiator cap while the cooling
system is hot. The system is under pressure and hot 2. Allow coolant to drain from the radiator and detach
coolant can cause severe burns or eye injury. Wear line from bottom of coolant overflow bottle and
protective clothing and safety glasses. Always turn drain bottle.
the cap slowly to the first stop and allow the pressure 3. Flush system with clean water and drain again.
to escape before removing the cap completely.
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 and
close petcock on the radiator. Reconnect heater
hose.
5. Fill radiator completely with 50/50 mixture of
ethylene glycol and water. Total System Capacity
is 4 gallons (15,1 ltr). Add coolant to overflow
bottle until bottle is about 1/2 to 3/4 full [approxi-
mately 2 qts. (1,9 ltr)]. This “overfilling” will
compensate for any air in the cooling system.
6. Clean dirt and debris from radiator fins and core, if
PETCOCK
required.

Figure 28 OH0261

8042 Rev 3/04 Page 59

B. Drain and Flush Radiator (1000 Hours or Annually) 1. Open rear radiator door. Remove radiator cap and
open petcock at bottom center of radiator (Figure
28).
WARNING NOTE: Attach a hose to the petcock to allow draining
directly into a container.
NEVER remove the radiator cap while the cooling
system is hot. The system is under pressure and hot 2. Allow coolant to drain from the radiator and detach
coolant can cause severe burns or eye injury. Wear line from bottom of coolant overflow bottle and
protective clothing and safety glasses. Always turn drain bottle.
the cap slowly to the first stop and allow the pressure 3. Flush system with clean water and drain again.
to escape before removing the cap completely.
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 and
close petcock on the radiator. Reconnect heater
hose.
5. Fill radiator completely with 50/50 mixture of
ethylene glycol and water. Total System Capacity
is 4 gallons (15,1 ltr). Add coolant to overflow
bottle until bottle is about 1/2 to 3/4 full [approxi-
mately 2 qts. (1,9 ltr)]. This “overfilling” will
compensate for any air in the cooling system.
6. Clean dirt and debris from radiator fins and core, if
PETCOCK
required.

Figure 28 OH0261

8042 Rev 3/04 Page 59

 7. Start engine and run vehicle to normal operating
Engine Oil Type Ambient Temperature
temperature. Allow engine to cool to ambient
temperature. Check radiator coolant level and top 10W30 Below 23° F (-5° C)
off completely. Replace radiator cap. Overflow 15W40 Above 23° F (-5° C)
bottle should be 1/4 to 1/2 full. If it is not, add
coolant to overflow bottle. Close and lock all
access doors. CROSSHATCHED
AREA
4. Engine Oil and Filter
A. Level Check (Daily or 10 Hour Intervals)
1. Level the vehicle, ground the carriage, place the F
U
L
L

travel select lever in (N) NEUTRAL, move the

neutral lock lever to NEUTRAL LOCK position, 1
Q
T

D
engage the emergency brake switch and shut off A
D

OG0290
the engine. Figure 29
2. Unlock and open right rear engine access door.
3. Remove dipstick and check mark on dipstick
(Figure 29). Oil should be within the crosshatched
area.
4. If oil is low, remove oil fill cap (Figure 27) and add
15W40 or 10W30 motor oil that is equal to API, CD
ENGINE OIL
or CE (severe duty diesel engine) specifications to FILTER 072465

bring oil up to the FULL mark in the crosshatched

0

3102
390

area. Replace oil fill cap and dipstick. Close and

lock access door.
Figure 30 OG0031

Page 60 8042 Rev 3/04

7. Start engine and run vehicle to normal operating

Engine Oil Type Ambient Temperature
temperature. Allow engine to cool to ambient
temperature. Check radiator coolant level and top 10W30 Below 23° F (-5° C)
off completely. Replace radiator cap. Overflow 15W40 Above 23° F (-5° C)
bottle should be 1/4 to 1/2 full. If it is not, add
coolant to overflow bottle. Close and lock all
access doors. CROSSHATCHED
AREA
4. Engine Oil and Filter
A. Level Check (Daily or 10 Hour Intervals)
1. Level the vehicle, ground the carriage, place the F
U
L
L

travel select lever in (N) NEUTRAL, move the

neutral lock lever to NEUTRAL LOCK position, 1
Q
T

D
engage the emergency brake switch and shut off A
D

OG0290
the engine. Figure 29
2. Unlock and open right rear engine access door.
3. Remove dipstick and check mark on dipstick
(Figure 29). Oil should be within the crosshatched
area.
4. If oil is low, remove oil fill cap (Figure 27) and add
15W40 or 10W30 motor oil that is equal to API, CD
ENGINE OIL
or CE (severe duty diesel engine) specifications to FILTER 072465

bring oil up to the FULL mark in the crosshatched

0

3102
390

area. Replace oil fill cap and dipstick. Close and

lock access door.
Figure 30 OG0031

Page 60 8042 Rev 3/04

B. Oil and Filter Change (250 Hour Intervals) NOTE: The filter o-ring may stick to the filter head.
IMPORTANT: The use of quality engine oil combined Make sure the old o-ring is removed before installing the
with appropriate oil and filter change intervals are new filter.
critical factors in maintaining engine performance and 8. Apply a thin coat of clean engine oil to seal on
durability. The use of multi-viscosity, 15W40, oil is new filter.
recommended for most climates. Low viscosity, 9. Install the new oil filter and hand tighten 1/2 turn
10W30, oil may be used at colder temperatures. after initial contact.
However, continuous use of low viscosity oil may
decrease engine life due to wear. 10. Clean and re-install oil pan drain plug.
1. Operate engine until warm (approximately 5 11. Remove oil fill cap (Figure 27) and add 15W40 or
minutes). 10W30 motor oil that is equal to API, CD or CE
specifications. (Reference engine manufacturer's
2. Level the vehicle, ground the carriage, place the
manual for recommended oil types to be used in
travel select lever in (N) NEUTRAL, move neutral
various temperature limits.) DO NOT over fill.
lock lever to NEUTRAL LOCK position, engage
Engine oil capacity with filter change is 11.6 qts.
the emergency brake switch and shut off the
engine. (11 ltr).
3. Place receptacle under engine oil pan drain. 12. Clear all personnel from area. Start engine and
4. Remove drain plug from engine oil pan. run for several minutes.
5. Allow oil to drain completely into a receptacle. 13. Stop engine. Let the oil drain back for a few
Transfer the oil to a container with a cover and minutes. Check oil level on dipstick (Figure 29)
label the container as used oil. Dispose of the and check for leaks at filter and drain plug.
used oil at an approved recycling facility. Retighten filter or drain plug if necessary.
6. Unlock and open the left engine access door.
14. Add oil to bring oil level up to the FULL mark in
Remove oil filter (Figure 30). A strap or chain
filter wrench may be required. the crosshatched area. Replace dipstick and oil
fill cap. Close and lock access door.
7. Clean filter sealing surface.

8042 Rev 3/04 Page 61

B. Oil and Filter Change (250 Hour Intervals) NOTE: The filter o-ring may stick to the filter head.
IMPORTANT: The use of quality engine oil combined Make sure the old o-ring is removed before installing the
with appropriate oil and filter change intervals are new filter.
critical factors in maintaining engine performance and 8. Apply a thin coat of clean engine oil to seal on
durability. The use of multi-viscosity, 15W40, oil is new filter.
recommended for most climates. Low viscosity, 9. Install the new oil filter and hand tighten 1/2 turn
10W30, oil may be used at colder temperatures. after initial contact.
However, continuous use of low viscosity oil may
decrease engine life due to wear. 10. Clean and re-install oil pan drain plug.
1. Operate engine until warm (approximately 5 11. Remove oil fill cap (Figure 27) and add 15W40 or
minutes). 10W30 motor oil that is equal to API, CD or CE
specifications. (Reference engine manufacturer's
2. Level the vehicle, ground the carriage, place the
manual for recommended oil types to be used in
travel select lever in (N) NEUTRAL, move neutral
various temperature limits.) DO NOT over fill.
lock lever to NEUTRAL LOCK position, engage
Engine oil capacity with filter change is 11.6 qts.
the emergency brake switch and shut off the
engine. (11 ltr).
3. Place receptacle under engine oil pan drain. 12. Clear all personnel from area. Start engine and
4. Remove drain plug from engine oil pan. run for several minutes.
5. Allow oil to drain completely into a receptacle. 13. Stop engine. Let the oil drain back for a few
Transfer the oil to a container with a cover and minutes. Check oil level on dipstick (Figure 29)
label the container as used oil. Dispose of the and check for leaks at filter and drain plug.
used oil at an approved recycling facility. Retighten filter or drain plug if necessary.
6. Unlock and open the left engine access door.
14. Add oil to bring oil level up to the FULL mark in
Remove oil filter (Figure 30). A strap or chain
filter wrench may be required. the crosshatched area. Replace dipstick and oil
fill cap. Close and lock access door.
7. Clean filter sealing surface.

8042 Rev 3/04 Page 61

 5. Engine Fuel System
A. Fuel Types
OH0480
FUEL
When operating at temperatures above 32° F (0° C) use FILL
standard #2 diesel fuel. ACCESS
DOOR
When operating at temperatures below 32° F (0° C)
use a blend of No. 1 diesel and No. 2 diesel fuels, 4108302

most commonly known as “winterized” No. 2 diesel

fuel. Use ASTM No. 2 diesel fuel with a minimum
Cetane number of 40. No. 2 diesel fuel gives the best
economy and performance under most operating Figure 31 OH0393
conditions. Fuels with Cetane numbers higher than
40 may be needed in high altitudes or extremely low B. Fuel Tank (Daily Before Operation)
ambient temperatures to prevent misfires and ex- Check fuel supply daily before operation. Open fuel fill
cessive smoke. access door with key (Figure 31). Remove fill cap on
tank and fill as required. Replace cap and lock access
door. Tank capacity is 35.5 gals. (134,4 ltr), total of
WARNING 33.5 (126,8 ltr) usable gals.
C. Fuel System Service
Engine fuel is flammable and can cause a fire or an
explosion. Keep sparks and open flames away from 1. Drain water from fuel water separator daily or
the vehicle and do not use smoking materials during 10 hour intervals. Unlock and open the right rear
refueling or servicing of the fuel system. engine access door. Loosen drain valve on under
side of the water separator (Figure 32) and allow all
water to drain into a glass until clear fuel is visible.
Tighten drain valve after draining. Close and lock
access door.

Page 62 8042 Rev 3/04

5. Engine Fuel System

A. Fuel Types
OH0480
FUEL
When operating at temperatures above 32° F (0° C) use FILL
standard #2 diesel fuel. ACCESS
DOOR
When operating at temperatures below 32° F (0° C)
use a blend of No. 1 diesel and No. 2 diesel fuels, 4108302

most commonly known as “winterized” No. 2 diesel

fuel. Use ASTM No. 2 diesel fuel with a minimum
Cetane number of 40. No. 2 diesel fuel gives the best
economy and performance under most operating Figure 31 OH0393
conditions. Fuels with Cetane numbers higher than
40 may be needed in high altitudes or extremely low B. Fuel Tank (Daily Before Operation)
ambient temperatures to prevent misfires and ex- Check fuel supply daily before operation. Open fuel fill
cessive smoke. access door with key (Figure 31). Remove fill cap on
tank and fill as required. Replace cap and lock access
door. Tank capacity is 35.5 gals. (134,4 ltr), total of
WARNING 33.5 (126,8 ltr) usable gals.
C. Fuel System Service
Engine fuel is flammable and can cause a fire or an
explosion. Keep sparks and open flames away from 1. Drain water from fuel water separator daily or
the vehicle and do not use smoking materials during 10 hour intervals. Unlock and open the right rear
refueling or servicing of the fuel system. engine access door. Loosen drain valve on under
side of the water separator (Figure 32) and allow all
water to drain into a glass until clear fuel is visible.
Tighten drain valve after draining. Close and lock
access door.

Page 62 8042 Rev 3/04

 2. Change fuel filter elements as needed every
FUEL FILTER/WATER
250 - (500 maximum) hours of operation. Fuel SEPARATOR
filter changes must be more often with water
evidence or contaminated fuel. Unlock and open
the right rear engine access door. Clean the area
around the fuel filter/water separator head. DRAIN VALVE
Remove the pre-filter and fuel filter/water separa-
tor cannisters (Figure 32). Discard the filter
cannisters and sealing rings. Clean the sealing
surfaces of the filter head. Fill the new cannisters
with clean No. 2 Diesel Fuel and lubricate the FUEL
sealing rings with clean lubricating oil. Install the PRE-FILTER
filters by hand tightening only. DO NOT over
tighten. Close and lock access door.

NOTE: Mechanical over-tightening may distort the

OH3730
threads or damage the sealing rings. Figure 32
Controlled venting is provided at the injection pump
through the fuel drain manifold. Small amounts of air 3. Replace fuel pre-filter every 1000 hours or
introduced by changing the filter elements will be annually. Unlock and open the right rear access
vented automatically as long as the elements were door. Replace the fuel pre-filter that is installed in
filled with fuel prior to installation. the fuel line (Figure 32).

NOTE: Marginal fuel cleanliness conditions will require

fuel system service more often. Loss of engine power
is often caused by dirty fuel filters.

8042 Rev 3/04 Page 63

2. Change fuel filter elements as needed every

FUEL FILTER/WATER
250 - (500 maximum) hours of operation. Fuel SEPARATOR
filter changes must be more often with water
evidence or contaminated fuel. Unlock and open
the right rear engine access door. Clean the area
around the fuel filter/water separator head. DRAIN VALVE
Remove the pre-filter and fuel filter/water separa-
tor cannisters (Figure 32). Discard the filter
cannisters and sealing rings. Clean the sealing
surfaces of the filter head. Fill the new cannisters
with clean No. 2 Diesel Fuel and lubricate the FUEL
sealing rings with clean lubricating oil. Install the PRE-FILTER
filters by hand tightening only. DO NOT over
tighten. Close and lock access door.

NOTE: Mechanical over-tightening may distort the

OH3730
threads or damage the sealing rings. Figure 32
Controlled venting is provided at the injection pump
through the fuel drain manifold. Small amounts of air 3. Replace fuel pre-filter every 1000 hours or
introduced by changing the filter elements will be annually. Unlock and open the right rear access
vented automatically as long as the elements were door. Replace the fuel pre-filter that is installed in
filled with fuel prior to installation. the fuel line (Figure 32).

NOTE: Marginal fuel cleanliness conditions will require

fuel system service more often. Loss of engine power
is often caused by dirty fuel filters.

8042 Rev 3/04 Page 63

D. Bleeding Fuel System
VENT SCREW
Manual venting of the fuel system is required if the fuel
filter is not filled prior to installation, the injection pump
is replaced, the high pressure fuel lines are loosened or
replaced, the fuel tank has run completely empty, or it
is the initial engine start up after an extended period of
no engine operation.

WARNING
Do not bleed a hot engine as this can cause fuel to
spill, creating a danger of fire.
IMPORTANT: DO NOT start the engine until the
injection pump has been filled and primed as serious
damage can be caused to the pump due to lack of
lubrication.
Remove air from the fuel system as follows:
NOTE: More than one person will be required to FUEL LIFT
perform this procedure. PUMP HAND PLUNGER

1. To vent the low pressure lines and fuel filters, open Figure 33 OH3730

the vent screw (Figure 33). Operate the hand

plunger on the lift pump, until the fuel flowing from
the fitting is free of air. Tighten the vent screw and
torque it to 6 lb-ft (8 Nm).

Page 64 8042 Rev 3/04

D. Bleeding Fuel System

VENT SCREW
Manual venting of the fuel system is required if the fuel
filter is not filled prior to installation, the injection pump
is replaced, the high pressure fuel lines are loosened or
replaced, the fuel tank has run completely empty, or it
is the initial engine start up after an extended period of
no engine operation.

WARNING
Do not bleed a hot engine as this can cause fuel to
spill, creating a danger of fire.
IMPORTANT: DO NOT start the engine until the
injection pump has been filled and primed as serious
damage can be caused to the pump due to lack of
lubrication.
Remove air from the fuel system as follows:
NOTE: More than one person will be required to FUEL LIFT
perform this procedure. PUMP HAND PLUNGER

1. To vent the low pressure lines and fuel filters, open Figure 33 OH3730

the vent screw (Figure 33). Operate the hand

plunger on the lift pump, until the fuel flowing from
the fitting is free of air. Tighten the vent screw and
torque it to 6 lb-ft (8 Nm).

Page 64 8042 Rev 3/04

 CAUTION INJECTOR HIGH
PRESSURE
LINE FITTINGS
When using the starting motor to vent the system,
DO NOT energize starter solenoid or crank the
engine for more than 15 seconds at a time; wait two
minutes between engagements.

WARNING
Fuel will spray when venting high pressure fuel lines.
Keep clear of spraying fuel. The pressure of the fuel
in the high pressure lines is sufficient to penetrate
the skin and cause serious bodily injury. Wear
protective clothing and safety glasses. Figure 34 MA1870

2. To vent the high pressure fuel lines, loosen one

fitting at a time at the injectors (Figure 34). Turn
the ignition key to the START position and crank
the engine for a maximum of 15 seconds or until
fuel, free from air, comes from the injector fitting.
Tighten the fitting. Repeat procedure for each
fitting until engine starts and runs smoothly. With
engine running, visually check for any leaks. Turn
ignition switch OFF.

8042 Rev 3/04 Page 65

CAUTION INJECTOR HIGH

PRESSURE
LINE FITTINGS
When using the starting motor to vent the system,
DO NOT energize starter solenoid or crank the
engine for more than 15 seconds at a time; wait two
minutes between engagements.

WARNING
Fuel will spray when venting high pressure fuel lines.
Keep clear of spraying fuel. The pressure of the fuel
in the high pressure lines is sufficient to penetrate
the skin and cause serious bodily injury. Wear
protective clothing and safety glasses. Figure 34 MA1870

2. To vent the high pressure fuel lines, loosen one

fitting at a time at the injectors (Figure 34). Turn
the ignition key to the START position and crank
the engine for a maximum of 15 seconds or until
fuel, free from air, comes from the injector fitting.
Tighten the fitting. Repeat procedure for each
fitting until engine starts and runs smoothly. With
engine running, visually check for any leaks. Turn
ignition switch OFF.

8042 Rev 3/04 Page 65

 6. Engine Fan Belt Check 4. Inspect fan belt. Replace cracked or frayed belt.
(1000 Hour Intervals) Transverse (across belt width) cracks are accept-
able. Longitudinal (along belt length) cracks are
Check fan belt condition as follows: not acceptable.
1. Ground the carriage, place the travel select lever 5. Check tensioner bearing. Spin the bearing and
in (N) NEUTRAL, move neutral lock lever to check that there are no rough spots detected under
NEUTRAL LOCK position, engage emergency hand pressure.
brake switch and shut off the engine.
6. Check the fan hub bearing. Spin the fan and
2. Unlock and open the left rear engine access door. check for wobble or excessive play. Maximum
3. Remove the fan belt (Figure 35) by carefully lifting end play should be 0.006 in. (0,15 mm).
the tensioner with a 1/2 inch square drive installed 7. To install the fan belt, first position the belt over
in square hole in tensioner bracket. the grooved pulleys and then, while holding up the
tensioner, slide the belt over the water pump
TENSIONER
BRACKET pulley.
8. Close and lock access door.
FAN
BELT

Figure 35 MA1881

Page 66 8042 Rev 3/04

6. Engine Fan Belt Check 4. Inspect fan belt. Replace cracked or frayed belt.
(1000 Hour Intervals) Transverse (across belt width) cracks are accept-
able. Longitudinal (along belt length) cracks are
Check fan belt condition as follows: not acceptable.
1. Ground the carriage, place the travel select lever 5. Check tensioner bearing. Spin the bearing and
in (N) NEUTRAL, move neutral lock lever to check that there are no rough spots detected under
NEUTRAL LOCK position, engage emergency hand pressure.
brake switch and shut off the engine.
6. Check the fan hub bearing. Spin the fan and
2. Unlock and open the left rear engine access door. check for wobble or excessive play. Maximum
3. Remove the fan belt (Figure 35) by carefully lifting end play should be 0.006 in. (0,15 mm).
the tensioner with a 1/2 inch square drive installed 7. To install the fan belt, first position the belt over
in square hole in tensioner bracket. the grooved pulleys and then, while holding up the
tensioner, slide the belt over the water pump
TENSIONER
BRACKET pulley.
8. Close and lock access door.
FAN
BELT

Figure 35 MA1881

Page 66 8042 Rev 3/04

 7. Hydraulic Oil and Filter ISO Grade 46 MIL-L-2104C
Hydraulic Oil 10W Motor Oil *
A. Hydraulic System Oil
Gulf Harmony 46 AW Castrol Deusol CRD
OH04601 Amoco Rykon 46 Esso Essolube D-3HP
Hydraulic system oil can be either a hydraulic oil Mobil DTE-25 Esso Essolube XD-3
Arco Duro AW S-215 Castrol Agricastrol HDD
meeting the requirements of ISO Grade 46 or a 10W Shell Tullus 46 Shell Rimula CT
motor oil meeting the requirements of U.S. Ordinance Benz Petraulic 46-7C Shell Rimula X
Specification MIL-L-2104C. See table on this page. Sun Sunvis 821 WR Shell Rimula TX
Chevron AW 46 * 5W20 Motor Oil may be
B. Level Check Texaco Rando HD 46 substituted for -30° F to
Citgo Pacemaker XD-46 70° F (-34 to 21° C) only.
(Daily or 10 Hour Intervals) OH04701

1. Be sure all cylinders are fully retracted and oil is

at room temperature.
2. Level the vehicle, ground the carriage, place
HYDRAULIC
travel select lever in (N) NEUTRAL, move the OIL TANK
neutral lock lever to NEUTRAL LOCK position, SIGHT GAUGE
engage the emergency brake switch and shut off
the engine.
3. Check level of hydraulic oil in tank at the sight
gauge on the back side of the hydraulic tank
(Figure 36). 4108302

4. The oil level should be visible in the gauge

window. If it is not, remove the reservoir cap and HYDRAULIC/
add ISO-46 or MIL-L-2104C oil (see table on this FUEL TANK
page). The hydraulic oil level should be within 1/2 CAPSCREWS COVER
inch of the upper mark on the sight gauge. Figure 36 OH0393
5. Install reservoir cap.
8042 Rev 3/04 Page 67

7. Hydraulic Oil and Filter ISO Grade 46 MIL-L-2104C

Hydraulic Oil 10W Motor Oil *
A. Hydraulic System Oil
Gulf Harmony 46 AW Castrol Deusol CRD
OH04601 Amoco Rykon 46 Esso Essolube D-3HP
Hydraulic system oil can be either a hydraulic oil Mobil DTE-25 Esso Essolube XD-3
Arco Duro AW S-215 Castrol Agricastrol HDD
meeting the requirements of ISO Grade 46 or a 10W Shell Tullus 46 Shell Rimula CT
motor oil meeting the requirements of U.S. Ordinance Benz Petraulic 46-7C Shell Rimula X
Specification MIL-L-2104C. See table on this page. Sun Sunvis 821 WR Shell Rimula TX
Chevron AW 46 * 5W20 Motor Oil may be
B. Level Check Texaco Rando HD 46 substituted for -30° F to
Citgo Pacemaker XD-46 70° F (-34 to 21° C) only.
(Daily or 10 Hour Intervals) OH04701

1. Be sure all cylinders are fully retracted and oil is

at room temperature.
2. Level the vehicle, ground the carriage, place
HYDRAULIC
travel select lever in (N) NEUTRAL, move the OIL TANK
neutral lock lever to NEUTRAL LOCK position, SIGHT GAUGE
engage the emergency brake switch and shut off
the engine.
3. Check level of hydraulic oil in tank at the sight
gauge on the back side of the hydraulic tank
(Figure 36). 4108302

4. The oil level should be visible in the gauge

window. If it is not, remove the reservoir cap and HYDRAULIC/
add ISO-46 or MIL-L-2104C oil (see table on this FUEL TANK
page). The hydraulic oil level should be within 1/2 CAPSCREWS COVER
inch of the upper mark on the sight gauge. Figure 36 OH0393
5. Install reservoir cap.
8042 Rev 3/04 Page 67
C. Oil Change
NUTS
Change hydraulic oil filter after the first 50 hours of
operation and every 1000 hours thereafter.
FILTER
Replace hydraulic oil annually or as required. HEAD
Oil must be cool before changing.
Other than the annual interval, the hydraulic oil must
be changed when a hydraulic component has contami-
nated the system. 4108302

1. Level the vehicle, ground the carriage, place travel HYDRAULIC

OIL FILL
select lever in (N) NEUTRAL, move the neutral
Figure 37 OH0402
lock lever to NEUTRAL LOCK position, engage the
emergency brake switch and shut off the engine.
6. If hydraulic oil is to be changed, retract all cylin-
2. Remove the four capscrews that fasten the tank ders, place a receptacle under the reservoir drain
cover to the hydraulic/fuel tank and remove the plug. Remove magnetic drain plug and allow oil to
tank cover (Figure 36). Clean area around filter drain into receptacle. Clean loose particles from
head. Unscrew the nuts (Figure 37) that secure the plug. Transfer the oil to a container with a cover
filter head to the hydraulic tank. and label the container as used oil. Dispose of the
3. Remove the filter head, element and gasket from oil at an approved recycling facility.
the tank. 7. Re-install magnetic drain plug into reservoir.
4. Pull the element off of the filter head and discard 8. Push new filter element fully onto the filter head
the element. until it seats against the washer. Re-install filter
5. Clean filter head sealing surfaces. head assembly and gasket into the tank and
secure with the nuts removed earlier.

Page 68 8042 Rev 3/04

C. Oil Change
NUTS
Change hydraulic oil filter after the first 50 hours of
operation and every 1000 hours thereafter.
FILTER
Replace hydraulic oil annually or as required. HEAD
Oil must be cool before changing.
Other than the annual interval, the hydraulic oil must
be changed when a hydraulic component has contami-
nated the system. 4108302

1. Level the vehicle, ground the carriage, place travel HYDRAULIC

OIL FILL
select lever in (N) NEUTRAL, move the neutral
Figure 37 OH0402
lock lever to NEUTRAL LOCK position, engage the
emergency brake switch and shut off the engine.
6. If hydraulic oil is to be changed, retract all cylin-
2. Remove the four capscrews that fasten the tank ders, place a receptacle under the reservoir drain
cover to the hydraulic/fuel tank and remove the plug. Remove magnetic drain plug and allow oil to
tank cover (Figure 36). Clean area around filter drain into receptacle. Clean loose particles from
head. Unscrew the nuts (Figure 37) that secure the plug. Transfer the oil to a container with a cover
filter head to the hydraulic tank. and label the container as used oil. Dispose of the
3. Remove the filter head, element and gasket from oil at an approved recycling facility.
the tank. 7. Re-install magnetic drain plug into reservoir.
4. Pull the element off of the filter head and discard 8. Push new filter element fully onto the filter head
the element. until it seats against the washer. Re-install filter
5. Clean filter head sealing surfaces. head assembly and gasket into the tank and
secure with the nuts removed earlier.

Page 68 8042 Rev 3/04

 9. Remove reservoir cap and fill the reservoir with 12. Loosen, but do not remove, the hydraulic line
ISO-46 or MIL-L-2104C Oil (see table on page 67) connection to the inlet port at the control valve
until the oil level is filled to the minimum oil level (this fitting may be an elbow or a tee).
as described in section 7B. Reservoir capacity is
30.3 gals. (114,7 ltr). 13. Prime the pump by cranking the engine until oil
free of air is dripping from the loosened hydraulic
line.

CAUTION 14. Tighten the hydraulic connection and reconnect the

wire to the fuel shutoff solenoid.
If the main hydraulic pump ever loses it's prime, 15. Run the vehicle and operate all hydraulic functions
serious damage to the pump and/or the entire hy- and then check for leaks.
draulic system may occur. The pump must be 16. Re-install the tank cover.
reprimed.

Use the following procedure whenever the pump requires that

it be reprimed. This procedure must be accomplished before
starting the engine.
T
OU
IN

10. Disconnect the wire from the fuel shutoff solenoid

on the engine.
11. Position catch container under the inlet pressure LOOSEN,
port (labeled IN) on the secondary control valve SECONDARY
BUT DO NOT REMOVE,
CONTROL VALVE
(Figure 38). THIS CONNECTION
SH0070
Figure 38

8042 Rev 3/04 Page 69

9. Remove reservoir cap and fill the reservoir with 12. Loosen, but do not remove, the hydraulic line
ISO-46 or MIL-L-2104C Oil (see table on page 67) connection to the inlet port at the control valve
until the oil level is filled to the minimum oil level (this fitting may be an elbow or a tee).
as described in section 7B. Reservoir capacity is
30.3 gals. (114,7 ltr). 13. Prime the pump by cranking the engine until oil
free of air is dripping from the loosened hydraulic
line.

CAUTION 14. Tighten the hydraulic connection and reconnect the

wire to the fuel shutoff solenoid.
If the main hydraulic pump ever loses it's prime, 15. Run the vehicle and operate all hydraulic functions
serious damage to the pump and/or the entire hy- and then check for leaks.
draulic system may occur. The pump must be 16. Re-install the tank cover.
reprimed.

Use the following procedure whenever the pump requires that

it be reprimed. This procedure must be accomplished before
starting the engine.
T
OU
IN

10. Disconnect the wire from the fuel shutoff solenoid

on the engine.
11. Position catch container under the inlet pressure LOOSEN,
port (labeled IN) on the secondary control valve SECONDARY
BUT DO NOT REMOVE,
CONTROL VALVE
(Figure 38). THIS CONNECTION
SH0070
Figure 38

8042 Rev 3/04 Page 69

 Top View of Transmission Compartment
8. Transmission Oil and Filter
TRANSMISSION
DIPSTICK A. Level Check (Daily)
1. Level the vehicle, ground the carriage, place travel
select lever in (N) NEUTRAL, move the neutral lock
lever to NEUTRAL LOCK position and engage the
emergency brake switch.
2. Check oil level with engine running at idle and oil at
normal operating temperature.
3. Remove transmission dipstick (Figure 39) through
access hole in transmission cover and check
reading.
4. Add 10W-30 Motor Oil (see table for approved
lubricants) to transmission as required to bring up
to full mark. Transmission capacity is 4.5 gallons
(17,0 ltr).
OH1180 Approved Lubricants
Figure 39 10W-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 ambient
temperatures below +14 °F (-10 °C)

Page 70 8042 Rev 3/04

Top View of Transmission Compartment

8. Transmission Oil and Filter
TRANSMISSION
DIPSTICK A. Level Check (Daily)
1. Level the vehicle, ground the carriage, place travel
select lever in (N) NEUTRAL, move the neutral lock
lever to NEUTRAL LOCK position and engage the
emergency brake switch.
2. Check oil level with engine running at idle and oil at
normal operating temperature.
3. Remove transmission dipstick (Figure 39) through
access hole in transmission cover and check
reading.
4. Add 10W-30 Motor Oil (see table for approved
lubricants) to transmission as required to bring up
to full mark. Transmission capacity is 4.5 gallons
(17,0 ltr).
OH1180 Approved Lubricants
Figure 39 10W-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 ambient
temperatures below +14 °F (-10 °C)

Page 70 8042 Rev 3/04

B. Filter Change (At First 50 Hours of Use and 1000 C. Oil Change (At First 50 Hours of Use and 1000 Hour
Hour Intervals Thereafter) Intervals Thereafter)
1. Level the vehicle, ground the carriage, place travel 1. Level the vehicle, ground the carriage, place the
select lever in (N) NEUTRAL, move the neutral travel select lever in (N) NEUTRAL, move the neutral
lock lever to NEUTRAL LOCK position, engage the lock lever to NEUTRAL LOCK position, engage the
emergency brake switch and shut off emergency brake switch and shut off engine.
the engine.
2. Place a pan or receptacle under the transmission
drop box (Figure 40) to catch fluid when the filter is
removed.
3. Remove the transmission filter cover from the
bottom of the transmission drop box.
TRANSMISSION
4. Remove the old filter element and o-rings. DRAIN PLUG
TRANSMISSION
5. Apply a thin film of clean 10W-30 Motor Oil (see FILTER COVER
table of approved lubricants on page 70) to the new
element o-rings. TRANSMISSION
FILTER
6. Install new element into transmission drop box.
Install transmission filter cover.
7. Remove and discard drained fluid. Transfer the oil
to a container with a cover and label the container
as used oil. Dispose of the used oil at an ap-
proved recycling facility. O-RINGS
8. Check transmission level and add 10W-30 Motor
Oil (see table of approved lubricants on page 70)
as required following procedures in paragraph 8A.
Figure 40 OH1200

8042 Rev 3/04 Page 71

B. Filter Change (At First 50 Hours of Use and 1000 C. Oil Change (At First 50 Hours of Use and 1000 Hour
Hour Intervals Thereafter) Intervals Thereafter)
1. Level the vehicle, ground the carriage, place travel 1. Level the vehicle, ground the carriage, place the
select lever in (N) NEUTRAL, move the neutral travel select lever in (N) NEUTRAL, move the neutral
lock lever to NEUTRAL LOCK position, engage the lock lever to NEUTRAL LOCK position, engage the
emergency brake switch and shut off emergency brake switch and shut off engine.
the engine.
2. Place a pan or receptacle under the transmission
drop box (Figure 40) to catch fluid when the filter is
removed.
3. Remove the transmission filter cover from the
bottom of the transmission drop box.
TRANSMISSION
4. Remove the old filter element and o-rings. DRAIN PLUG
TRANSMISSION
5. Apply a thin film of clean 10W-30 Motor Oil (see FILTER COVER
table of approved lubricants on page 70) to the new
element o-rings. TRANSMISSION
FILTER
6. Install new element into transmission drop box.
Install transmission filter cover.
7. Remove and discard drained fluid. Transfer the oil
to a container with a cover and label the container
as used oil. Dispose of the used oil at an ap-
proved recycling facility. O-RINGS
8. Check transmission level and add 10W-30 Motor
Oil (see table of approved lubricants on page 70)
as required following procedures in paragraph 8A.
Figure 40 OH1200

8042 Rev 3/04 Page 71

 2. Place a funnel with flexible drain under the trans-
mission housing (Figure 40) and a receptacle to 9. Axle Oil
catch fluid. A. Level Check (250 Hour Intervals)
3. Remove transmission drain plug (Figure 40) and 1. Level the vehicle, ground the carriage, place the
allow the oil to drain completely. Transfer the oil to travel select lever in (N) NEUTRAL, move the
a container with a cover and label the container as neutral lock lever to NEUTRAL LOCK position,
used oil. Dispose of the used oil at an approved engage the emergency brake switch and shut off
recycling facility. engine.
4. Clean drain plug thoroughly with a standard sol- 2. Clean area around axle fill/level plug, remove plug
vent. (Figure 41) from axle housing and check oil level.
5. Install new filter element by following procedures in Add 80W90 gear oil as required to bring the oil
paragraph 8B, but DO NOT start engine at this level up even with the plug hole (for temperatures
time. below -15° F (-26° C) 75W gear oil can be used).
6. Install cleaned drain plug into long drop case. 3. Reinstall plug.
Remove and discard old fluid in receptacle.
7. Fill transmission to the LOW mark on the dipstick.
Check transmission level and add 10W-30 Motor
Oil as required following procedures in paragraph
8A.
AXLE
FILL/LEVEL
PLUG AXLE DRAIN PLUG
Figure 41 OH0030

Page 72 8042 Rev 3/04

2. Place a funnel with flexible drain under the trans-

mission housing (Figure 40) and a receptacle to 9. Axle Oil
catch fluid. A. Level Check (250 Hour Intervals)
3. Remove transmission drain plug (Figure 40) and 1. Level the vehicle, ground the carriage, place the
allow the oil to drain completely. Transfer the oil to travel select lever in (N) NEUTRAL, move the
a container with a cover and label the container as neutral lock lever to NEUTRAL LOCK position,
used oil. Dispose of the used oil at an approved engage the emergency brake switch and shut off
recycling facility. engine.
4. Clean drain plug thoroughly with a standard sol- 2. Clean area around axle fill/level plug, remove plug
vent. (Figure 41) from axle housing and check oil level.
5. Install new filter element by following procedures in Add 80W90 gear oil as required to bring the oil
paragraph 8B, but DO NOT start engine at this level up even with the plug hole (for temperatures
time. below -15° F (-26° C) 75W gear oil can be used).
6. Install cleaned drain plug into long drop case. 3. Reinstall plug.
Remove and discard old fluid in receptacle.
7. Fill transmission to the LOW mark on the dipstick.
Check transmission level and add 10W-30 Motor
Oil as required following procedures in paragraph
8A.
AXLE
FILL/LEVEL
PLUG AXLE DRAIN PLUG
Figure 41 OH0030

Page 72 8042 Rev 3/04

B. Oil Change (1000 Hour Intervals)
1. Level the vehicle, ground the carriage, place the
10. Wheel End Oil
travel select lever in (N) NEUTRAL, move the
neutral lock lever to NEUTRAL LOCK position,
engage the emergency brake switch and shut off
engine.
WARNING
2. Clean area around axle fill/level plug and drain DO NOT perform service or maintenance on the vehicle
plug. with the engine running. Contact with moving parts can
3. Place receptacle under the axle housing drain plug. cause serious injury or death.
Remove fill/level plug and drain plug from axle
housing. VENT PLUG
4. Allow oil to drain completely.
5. Clean and reinstall drain plug.
6. Fill axle to level plug hole with 80W90 gear oil (for FILL

temperatures below -15° F (-26° C) 75W gear oil ARROW DOWN

TO FILL/CHECK OIL LEVEL

can be used). Axle capacity is 18 qts. (17 ltr).

MAGNETIC
7. Install fill/level plug. WHEEL END
ARROW DOWN
DRAIN PLUG
TO FILL/CHECK OIL LEVEL FILL

Figure 42 OA0432

8042 Rev 3/04 Page 73

B. Oil Change (1000 Hour Intervals)

1. Level the vehicle, ground the carriage, place the
10. Wheel End Oil
travel select lever in (N) NEUTRAL, move the
neutral lock lever to NEUTRAL LOCK position,
engage the emergency brake switch and shut off
engine.
WARNING
2. Clean area around axle fill/level plug and drain DO NOT perform service or maintenance on the vehicle
plug. with the engine running. Contact with moving parts can
3. Place receptacle under the axle housing drain plug. cause serious injury or death.
Remove fill/level plug and drain plug from axle
housing. VENT PLUG
4. Allow oil to drain completely.
5. Clean and reinstall drain plug.
6. Fill axle to level plug hole with 80W90 gear oil (for FILL

temperatures below -15° F (-26° C) 75W gear oil ARROW DOWN

TO FILL/CHECK OIL LEVEL

can be used). Axle capacity is 18 qts. (17 ltr).

MAGNETIC
7. Install fill/level plug. WHEEL END
ARROW DOWN
DRAIN PLUG
TO FILL/CHECK OIL LEVEL FILL

Figure 42 OA0432

8042 Rev 3/04 Page 73

Oil Change (250 Hour Intervals) IMPORTANT: All wheel ends are factory filled with oil that
contains friction modifier. DO NOT add additional friction
1. Be sure that the drain plug on the wheel end
housing (Figure 42) is down. Level the vehicle, modifier to factory filled wheel ends. The addition of
ground the carriage, place the travel select lever in friction modifier to a factory fill will dilute the properties of
(N) NEUTRAL, move the neutral lock lever to the oil and could cause loss of braking ability. If a noisy
NEUTRAL LOCK position, engage the emergency brake condition exists after a fresh fill of oil add 6 ozs.
brake switch and shut off the engine. (0,18 ltr) of friction modifier per wheel end. NEVER add
2. Clean the areas around the magnetic drain plug and more than 6 ozs. (0,18 ltr) of friction modifier to any wheel
vent plug. end as to much modifier could cause loss of braking
ability. Brake noise is not harmful to the operation of the
3. Remove vent plug. wheel end brakes and any oil type may result in a certain
4. Remove the drain plug and allow the fluid to drain. amount of noise, especially during hard braking conditions.
5. Move the vehicle so the arrow on the wheel end
housing is pointing down (Figure 42). OIL BRAND NAME AND DESCRIPTION
*AMOCO Oil Company AMOCO 1000 Fluid
6. Fill the wheel end with recommended oil listed in P/N 8522045 (2.5 gal.)
table on this page to the level of the drain plug. J.I. CASE HY-TRAN TCH
Capacity of wheel end is approximately 54 ozs. JOHN DEERE J20
(1,6 ltr). FORD-NEW HOLLAND M2C-134
MOBIL FLUID 424
7. Clean and install drain plug and vent plug. Drain FRICTION MODIFIER BRAND PART NUMBER
and fill three remaining wheel ends using the same
*Sky Trak 8522043 (32 oz.)
procedure. Ford C8AZ19B546A (4 oz.)
* = Recommended Oil

Page 74 8042 Rev 3/04

Oil Change (250 Hour Intervals) IMPORTANT: All wheel ends are factory filled with oil that
contains friction modifier. DO NOT add additional friction
1. Be sure that the drain plug on the wheel end
housing (Figure 42) is down. Level the vehicle, modifier to factory filled wheel ends. The addition of
ground the carriage, place the travel select lever in friction modifier to a factory fill will dilute the properties of
(N) NEUTRAL, move the neutral lock lever to the oil and could cause loss of braking ability. If a noisy
NEUTRAL LOCK position, engage the emergency brake condition exists after a fresh fill of oil add 6 ozs.
brake switch and shut off the engine. (0,18 ltr) of friction modifier per wheel end. NEVER add
2. Clean the areas around the magnetic drain plug and more than 6 ozs. (0,18 ltr) of friction modifier to any wheel
vent plug. end as to much modifier could cause loss of braking
ability. Brake noise is not harmful to the operation of the
3. Remove vent plug. wheel end brakes and any oil type may result in a certain
4. Remove the drain plug and allow the fluid to drain. amount of noise, especially during hard braking conditions.
5. Move the vehicle so the arrow on the wheel end
housing is pointing down (Figure 42). OIL BRAND NAME AND DESCRIPTION
*AMOCO Oil Company AMOCO 1000 Fluid
6. Fill the wheel end with recommended oil listed in P/N 8522045 (2.5 gal.)
table on this page to the level of the drain plug. J.I. CASE HY-TRAN TCH
Capacity of wheel end is approximately 54 ozs. JOHN DEERE J20
(1,6 ltr). FORD-NEW HOLLAND M2C-134
MOBIL FLUID 424
7. Clean and install drain plug and vent plug. Drain FRICTION MODIFIER BRAND PART NUMBER
and fill three remaining wheel ends using the same
*Sky Trak 8522043 (32 oz.)
procedure. Ford C8AZ19B546A (4 oz.)
* = Recommended Oil

Page 74 8042 Rev 3/04

 11. Wheels and Tires
A. Air Pressure / Hydrofill Check
(Daily or 10 Hour Intervals)
WARNING
Improper hydrofill can cause instability which can result
IMPORTANT: Before checking air pressure be sure to in tipover. ALWAYS make sure that all four tires have
position the valve stem at the top of the wheel to prevent been properly filled with hydrofill by a qualified tire service
loss of hydrofill. To check hydrofill level, position valve so center.
that it is nearly, but not quite, at the top of the wheel. B. Filling with Hydrofill
Depress valve stem. Hydrofill should escape. If hydrofill Hydrofill is a mixture of water and calcium chloride
does not escape from the valve, see “Filling with Hydrofill.” and provides the vehicle with additional weight for
Clean the area around the valve stems and check air pres- stability. All hydrofill service to tires should be
sure at all four tires: performed by a qualified tire service center. Hydrofill
must be refilled after any tire repair. Refer to the
Size psi Air Pressure “Specifications” section for details of the hydrofill
13.00 - 24, 70 psi content required for each tire size. JLG assumes no
12 PLY (min.) (482 kPa) liability for damage or injury incurred while operating
without proper hydrofill in all four tires.
13.00 R24, RADIAL 80 psi C. Replacing Tires
(551 kPa)
15.5 - 25, 58 psi
12 PLY (min.) (400 kPa)
WARNING
Mis-Matched tire sizes or mixing of tire types (Radial
and Bias ply) may compromise vehicle stability and
may result in vehicle tipover.

8042 Rev 3/04 Page 75

11. Wheels and Tires

A. Air Pressure / Hydrofill Check
(Daily or 10 Hour Intervals)
WARNING
Improper hydrofill can cause instability which can result
IMPORTANT: Before checking air pressure be sure to in tipover. ALWAYS make sure that all four tires have
position the valve stem at the top of the wheel to prevent been properly filled with hydrofill by a qualified tire service
loss of hydrofill. To check hydrofill level, position valve so center.
that it is nearly, but not quite, at the top of the wheel. B. Filling with Hydrofill
Depress valve stem. Hydrofill should escape. If hydrofill Hydrofill is a mixture of water and calcium chloride
does not escape from the valve, see “Filling with Hydrofill.” and provides the vehicle with additional weight for
Clean the area around the valve stems and check air pres- stability. All hydrofill service to tires should be
sure at all four tires: performed by a qualified tire service center. Hydrofill
must be refilled after any tire repair. Refer to the
Size psi Air Pressure “Specifications” section for details of the hydrofill
13.00 - 24, 70 psi content required for each tire size. JLG assumes no
12 PLY (min.) (482 kPa) liability for damage or injury incurred while operating
without proper hydrofill in all four tires.
13.00 R24, RADIAL 80 psi C. Replacing Tires
(551 kPa)
15.5 - 25, 58 psi
12 PLY (min.) (400 kPa)
WARNING
Mis-Matched tire sizes or mixing of tire types (Radial
and Bias ply) may compromise vehicle stability and
may result in vehicle tipover.

8042 Rev 3/04 Page 75

The chart on page 75 depicts the minimum size and
ply ratings (star rating for radial tires) that should be 12. Battery (250 Hour Intervals)
used on this vehicle. Make sure the replacement tire
is of the same size and ply rating (star rating for radial
tires) as all other tires. Higher ply (star for radial)
rated tires can be used on this vehicle, but only when
WARNING
Lead-acid batteries produce flammable and explosive
all four tires have the same ply rating. gases. To avoid personal injury when checking, testing
or charging battery:
D. Wheel Lug Nuts (Torque At First 50 Hours Only) • DO NOT use smoking materials near battery.
• Keep arcs, sparks and flames away from battery.
Clean the area around all wheel lug nuts. Check and
• Provide ventilation and wear safety glasses.
torque wheel lug nuts to 450 - 500 lb-ft (610 - 678 Nm)
using the torque sequence (Figure 43). 1. Level the vehicle, ground the carriage, place the
travel select lever in (N) NEUTRAL, move the
neutral lock lever to NEUTRAL LOCK position,
1 5 engage the emergency brake switch and shut off the
engine.
9
7 2. Unlock the battery cover and lower or remove the
cover (Figure 44) to gain access to the battery.
3. The battery in this vehicle
3 4 is a maintenance free
type battery. It is shipped
in the vehicle filled with
10 8 electrolyte and charged.
OH1210
4. Replace battery if the
TIRE 6 2 OA0453 case is cracked, melted,
VALVE BATTERY key lock
Figure 43 or damaged. Check COVER Figure 44
terminals for corrosion.

Page 76 8042 Rev 3/04

The chart on page 75 depicts the minimum size and

ply ratings (star rating for radial tires) that should be 12. Battery (250 Hour Intervals)
used on this vehicle. Make sure the replacement tire
is of the same size and ply rating (star rating for radial
tires) as all other tires. Higher ply (star for radial)
rated tires can be used on this vehicle, but only when
WARNING
Lead-acid batteries produce flammable and explosive
all four tires have the same ply rating. gases. To avoid personal injury when checking, testing
or charging battery:
D. Wheel Lug Nuts (Torque At First 50 Hours Only) • DO NOT use smoking materials near battery.
• Keep arcs, sparks and flames away from battery.
Clean the area around all wheel lug nuts. Check and
• Provide ventilation and wear safety glasses.
torque wheel lug nuts to 450 - 500 lb-ft (610 - 678 Nm)
using the torque sequence (Figure 43). 1. Level the vehicle, ground the carriage, place the
travel select lever in (N) NEUTRAL, move the
neutral lock lever to NEUTRAL LOCK position,
1 5 engage the emergency brake switch and shut off the
engine.
9
7 2. Unlock the battery cover and lower or remove the
cover (Figure 44) to gain access to the battery.
3. The battery in this vehicle
3 4 is a maintenance free
type battery. It is shipped
in the vehicle filled with
10 8 electrolyte and charged.
OH1210
4. Replace battery if the
TIRE 6 2 OA0453 case is cracked, melted,
VALVE BATTERY key lock
Figure 43 or damaged. Check COVER Figure 44
terminals for corrosion.

Page 76 8042 Rev 3/04

 5. Battery Charging —

WARNING Under normal conditions the engine alternator will have

no problem keeping the battery charged. The only
Fluid in electric storage batteries contains sulfuric acid condition in which the battery may cause a problem is
which is POISON and can cause SEVERE CHEMI- when it has been completely discharged for an ex-
CAL BURNS. Avoid all contact of fluid with eyes, skin, tended period of time. Under these conditions the
or clothing. Use proper protective gear when handling alternator may be unable to recharge the battery. A
batteries. DO NOT tip any battery beyond a 45° angle battery charger will be required for recharging.
in any direction. If contact does occur, follow the First
Aid suggestions below. Before using a charger, an attempt can be made to
recharge the battery using the engine alternator by first
jump starting the vehicle and letting the engine run.
See “Jump Starting” instructions earlier in this manual.
Battery Electrolyte First Aid:
• External Contact — Flush with water.

• Eyes — Flush with water for at least 15 minutes

and get medical attention immediately!

• Internal Contact — Drink large quantities of

water. Follow with Milk of Magnesia, beaten egg
or vegetable oil. Get medical attention immedi-
ately!

IMPORTANT: In case of internal contact, DO NOT

give fluids that would induce vomiting!

8042 Rev 3/04 Page 77

5. Battery Charging —

WARNING Under normal conditions the engine alternator will have

no problem keeping the battery charged. The only
Fluid in electric storage batteries contains sulfuric acid condition in which the battery may cause a problem is
which is POISON and can cause SEVERE CHEMI- when it has been completely discharged for an ex-
CAL BURNS. Avoid all contact of fluid with eyes, skin, tended period of time. Under these conditions the
or clothing. Use proper protective gear when handling alternator may be unable to recharge the battery. A
batteries. DO NOT tip any battery beyond a 45° angle battery charger will be required for recharging.
in any direction. If contact does occur, follow the First
Aid suggestions below. Before using a charger, an attempt can be made to
recharge the battery using the engine alternator by first
jump starting the vehicle and letting the engine run.
See “Jump Starting” instructions earlier in this manual.
Battery Electrolyte First Aid:
• External Contact — Flush with water.

• Eyes — Flush with water for at least 15 minutes

and get medical attention immediately!

• Internal Contact — Drink large quantities of

water. Follow with Milk of Magnesia, beaten egg
or vegetable oil. Get medical attention immedi-
ately!

IMPORTANT: In case of internal contact, DO NOT

give fluids that would induce vomiting!

8042 Rev 3/04 Page 77

 13. Fuse and Relay Replacement
WARNING The fuses and relays in this vehicle protect the entire
DO NOT charge a frozen battery, it may explode and electrical system. The fuses most often fail if there is a
cause injury. Let the battery thaw out before putting on shorted or grounded wire in the applicable circuit. The
a charger. fuses will have to be replaced if they fail. If the fuses or
relays continually fail, check the system for shorts,
Charging rates between 3 and 50 amperes are satisfactory grounds or defective electrical components.
if excessive gassing or spewing of electrolyte does not
occur or the battery does not feel excessively hot [over
IMPORTANT: Be sure to shut off the engine and discon-
125° F (52° C)]. If spewing or gassing occurs or the
nect the negative battery cable before using an ohmmeter
temperature exceeds 125° F, the charging rate must be
to check the resistance of the electrical system.
reduced or temporarily stopped to permit cooling. The fuses (1-8) and relays (9-11) are located inside the
right console (Figure 45). The relays (12-14) are located
under the dash panel. Note that you will require a #T-27
TORX driver to remove the side console access panel.

Page 78 8042 Rev 3/04

13. Fuse and Relay Replacement

WARNING The fuses and relays in this vehicle protect the entire
DO NOT charge a frozen battery, it may explode and electrical system. The fuses most often fail if there is a
cause injury. Let the battery thaw out before putting on shorted or grounded wire in the applicable circuit. The
a charger. fuses will have to be replaced if they fail. If the fuses or
relays continually fail, check the system for shorts,
Charging rates between 3 and 50 amperes are satisfactory grounds or defective electrical components.
if excessive gassing or spewing of electrolyte does not
occur or the battery does not feel excessively hot [over
IMPORTANT: Be sure to shut off the engine and discon-
125° F (52° C)]. If spewing or gassing occurs or the
nect the negative battery cable before using an ohmmeter
temperature exceeds 125° F, the charging rate must be
to check the resistance of the electrical system.
reduced or temporarily stopped to permit cooling. The fuses (1-8) and relays (9-11) are located inside the
right console (Figure 45). The relays (12-14) are located
under the dash panel. Note that you will require a #T-27
TORX driver to remove the side console access panel.

Page 78 8042 Rev 3/04

 1
The following fuses and relays are used (See Figure 45).
2

12 3
11
No. Amp Circuit Protected 13 4
14 10 5
or Volt
1 10 amp Enclosed Cab Windshield Washer/Wiper 9 6
Switch and Circulation Fan (Optional this
8 7
fuse will not be found on vehicles with an
open cab)
SPARE
2 7.5 amp Stabil-TRAK Solenoids, Relays and FUSES
Proximity Switch
OH3710
Figure 45
3 7.5 amp Steering Select Circuit and Stabilizer Lock
Relay
No. Amp Circuit Protected
4 10 amp Horn and Back-up Alarm (Optional - Cab or Volt
Heater Fan) 9 12 volt Light Switch Relay (30 amp)
5 10 amp Warning Lights, Emergency Brake Switch, 10 12 volt Boom Switch Relay (40 amp)
Fuel Gauge and Hourmeter
11 12 volt Stabilizer Lock Relay (40 amp)
6 7.5 amp (Optional - Light Switch Relay) 12 12 volt Back-Up Alarm Relay (40 amp)
7 40 amp Ignition Switch Feed For Entire Electrical 13 12 volt Neutral Start Relay (40 amp)
System (Main)
14 12 volt Emergency Brake Disconnect
8 20 amp (Optional - Lighting Package) Relay (40 amp)

8042 Rev 3/04 Page 79

1
The following fuses and relays are used (See Figure 45).
2

12 3
11
No. Amp Circuit Protected 13 4
14 10 5
or Volt
1 10 amp Enclosed Cab Windshield Washer/Wiper 9 6
Switch and Circulation Fan (Optional this
8 7
fuse will not be found on vehicles with an
open cab)
SPARE
2 7.5 amp Stabil-TRAK Solenoids, Relays and FUSES
Proximity Switch
OH3710
Figure 45
3 7.5 amp Steering Select Circuit and Stabilizer Lock
Relay
No. Amp Circuit Protected
4 10 amp Horn and Back-up Alarm (Optional - Cab or Volt
Heater Fan) 9 12 volt Light Switch Relay (30 amp)
5 10 amp Warning Lights, Emergency Brake Switch, 10 12 volt Boom Switch Relay (40 amp)
Fuel Gauge and Hourmeter
11 12 volt Stabilizer Lock Relay (40 amp)
6 7.5 amp (Optional - Light Switch Relay) 12 12 volt Back-Up Alarm Relay (40 amp)
7 40 amp Ignition Switch Feed For Entire Electrical 13 12 volt Neutral Start Relay (40 amp)
System (Main)
14 12 volt Emergency Brake Disconnect
8 20 amp (Optional - Lighting Package) Relay (40 amp)

8042 Rev 3/04 Page 79

 14. Boom Chains and Wear Pads BOOM CHAIN SAG

A. Top Boom Chain Tension Check (First 50 Hours

Only, Then 1000 Hour Intervals Thereafter)

Check the boom chain tension by measuring the top

boom chain sag.

1. Raise the boom to a horizontal (level) position.

Fully extend the boom, then retract it 2" (50,8 mm)
(one inch per section).

2. Measure the sag in the top boom chains between CENTER SECTION
OF INTERMEDIATE BOOM
the bottom of the chains and the top of the inter-
mediate boom at their closest point (Figure 46).
Acceptable boom chain sag is between 1-1/2"
(38,1 mm) and 2-1/2" (63,5 mm). If the measure-
Figure 46 OA0492
ment is less than 1-1/2" (38,1 mm) , the boom
chains need to be adjusted. Follow procedures in
paragraph 14B to adjust.

Page 80 8042 Rev 3/04

14. Boom Chains and Wear Pads BOOM CHAIN SAG

A. Top Boom Chain Tension Check (First 50 Hours

Only, Then 1000 Hour Intervals Thereafter)

Check the boom chain tension by measuring the top

boom chain sag.

1. Raise the boom to a horizontal (level) position.

Fully extend the boom, then retract it 2" (50,8 mm)
(one inch per section).

2. Measure the sag in the top boom chains between CENTER SECTION
OF INTERMEDIATE BOOM
the bottom of the chains and the top of the inter-
mediate boom at their closest point (Figure 46).
Acceptable boom chain sag is between 1-1/2"
(38,1 mm) and 2-1/2" (63,5 mm). If the measure-
Figure 46 OA0492
ment is less than 1-1/2" (38,1 mm) , the boom
chains need to be adjusted. Follow procedures in
paragraph 14B to adjust.

Page 80 8042 Rev 3/04

B. Top Boom Chain Tension Adjustment FRONT OF BOOM
(As Required)
4-1/2 to 5-1/2"
1. Retract the boom completely to check the position
(114,3 to 139,7 mm)
of the inner boom. The inner boom section should
extend between 4-1/2" (114,3 mm) to 5-1/2"
(139,7 mm) beyond the end of the intermediate
INTERMEDIATE
boom section (Figure 47). If the measurement is BOOM
not between 4-1/2" (114,3 mm) and 5-1/2"
(139,7 mm), the boom may require more extensive INNER BOOM
adjustment and/or repair. Contact your authorized
Sky Trak distributor.

OH0230

Figure 47

8042 Rev 3/04 Page 81

B. Top Boom Chain Tension Adjustment FRONT OF BOOM

(As Required)
4-1/2 to 5-1/2"
1. Retract the boom completely to check the position
(114,3 to 139,7 mm)
of the inner boom. The inner boom section should
extend between 4-1/2" (114,3 mm) to 5-1/2"
(139,7 mm) beyond the end of the intermediate
INTERMEDIATE
boom section (Figure 47). If the measurement is BOOM
not between 4-1/2" (114,3 mm) and 5-1/2"
(139,7 mm), the boom may require more extensive INNER BOOM
adjustment and/or repair. Contact your authorized
Sky Trak distributor.

OH0230

Figure 47

8042 Rev 3/04 Page 81

 2. If the distance measured in Step 1 is 5" (127 mm)
or more, but less than 5-1/2" (139,7 mm);
a. Tighten the locknut (Figure 48) located on the
RETRACT CHAIN
bottom of the outer boom. LOCKNUT
b. Cycle the boom in and out, then, with the boom
horizontal (level), fully extend the boom and
retract 2" (50,8 mm) (one inch per section).
c. Measure the chain sag. Acceptable boom
chain sag is between 1-1/2" (38,1 mm) and
2-1/2" (63,5 mm). If the chain sag is less than EXTEND CYLINDER
1-1/2" (38,1 mm), repeat Steps “a” through “c”. OA0512
Figure 48
3. If the distance measured in Step 1 is less than
5" (127 mm) but greater than 4-1/2" (114,3 mm). To REAR OF BOOM 8-1/2" (216 mm)
check the 8-1/2" (216 mm) alternate dimension as (ALTERNATE MEASUREMENT)
INNER BOOM
shown in Figure 49 the rear cover has to be re-
moved. To adjust proceed as follows;
a. Remove the rear cover from the outer boom and MEASURE
adjust the top extend boom chains. FROM REAR
OF
b. Tighten the locknuts (Figure 50) for each chain. INTERMEDIATE
Be sure each locknut is tightened equally so BOOM TO
that each chain maintains the same tension. REAR OF
INNER BOOM
Equal chain tension can be checked by the
position of the yoke on the outer boom (Figure
51). The front of the yoke should be parallel INTERMEDIATE BOOM
with the front edge of the boom. OH1090
Figure 49

Page 82 8042 Rev 3/04

2. If the distance measured in Step 1 is 5" (127 mm)

or more, but less than 5-1/2" (139,7 mm);
a. Tighten the locknut (Figure 48) located on the
RETRACT CHAIN
bottom of the outer boom. LOCKNUT
b. Cycle the boom in and out, then, with the boom
horizontal (level), fully extend the boom and
retract 2" (50,8 mm) (one inch per section).
c. Measure the chain sag. Acceptable boom
chain sag is between 1-1/2" (38,1 mm) and
2-1/2" (63,5 mm). If the chain sag is less than EXTEND CYLINDER
1-1/2" (38,1 mm), repeat Steps “a” through “c”. OA0512
Figure 48
3. If the distance measured in Step 1 is less than
5" (127 mm) but greater than 4-1/2" (114,3 mm). To REAR OF BOOM 8-1/2" (216 mm)
check the 8-1/2" (216 mm) alternate dimension as (ALTERNATE MEASUREMENT)
INNER BOOM
shown in Figure 49 the rear cover has to be re-
moved. To adjust proceed as follows;
a. Remove the rear cover from the outer boom and MEASURE
adjust the top extend boom chains. FROM REAR
OF
b. Tighten the locknuts (Figure 50) for each chain. INTERMEDIATE
Be sure each locknut is tightened equally so BOOM TO
that each chain maintains the same tension. REAR OF
INNER BOOM
Equal chain tension can be checked by the
position of the yoke on the outer boom (Figure
51). The front of the yoke should be parallel INTERMEDIATE BOOM
with the front edge of the boom. OH1090
Figure 49

Page 82 8042 Rev 3/04

 WEAR PADS EXTEND CHAINS WEAR PADS
LOCKNUTS

BOOM EXTEND CHAINS

YOKE

RETRACT CHAIN
Figure 50 OH0252
Figure 51
OH0240

8042 Rev 3/04 Page 83

WEAR PADS EXTEND CHAINS WEAR PADS

LOCKNUTS

BOOM EXTEND CHAINS

YOKE

RETRACT CHAIN
Figure 50 OH0252
Figure 51
OH0240

8042 Rev 3/04 Page 83

 c. Cycle the boom in and out, then, with the C. Chain Lubrication (1000 Hour Intervals)
boom horizontal (level), fully extend the boom With the boom extended fully, apply “LPS - 3” or
and retract 2" (50,8 mm) (one inch per sec- “LUBRIPLATE” chain and cable fluid or equivalent to
tion). extend chains.
d. Measure the chain sag. Acceptable boom D. Wear Pad Check (50 Hour Intervals)
chain sag is between 1-1/2" (38,1 mm) and
2-1/2" (63,5 mm). If the chain sag is less Visually inspect boom wear pads between the boom
than 1-1/2" (38,1 mm), repeat Steps “a” sections at the rear and front of the boom for excessive
through “d”. wear at every 50 hour interval.
The average expected life of boom pads can vary depend-
e. Replace the rear outer boom cover. 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 the
loads are at or near maximum capacity, or if you are
operating in very dusty or dirty conditions, the boom pads
will wear much faster. The pads that are under the most
stress from the weight of the load will also wear faster than
other pads. For example, the lower pads at the front of the
boom are under far more stress than the pads attached to
the top, rear or sides of the boom. Consequently the lower
pads will require service more often.

Page 84 8042 Rev 3/04

c. Cycle the boom in and out, then, with the C. Chain Lubrication (1000 Hour Intervals)
boom horizontal (level), fully extend the boom With the boom extended fully, apply “LPS - 3” or
and retract 2" (50,8 mm) (one inch per sec- “LUBRIPLATE” chain and cable fluid or equivalent to
tion). extend chains.
d. Measure the chain sag. Acceptable boom D. Wear Pad Check (50 Hour Intervals)
chain sag is between 1-1/2" (38,1 mm) and
2-1/2" (63,5 mm). If the chain sag is less Visually inspect boom wear pads between the boom
than 1-1/2" (38,1 mm), repeat Steps “a” sections at the rear and front of the boom for excessive
through “d”. wear at every 50 hour interval.
The average expected life of boom pads can vary depend-
e. Replace the rear outer boom cover. 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 the
loads are at or near maximum capacity, or if you are
operating in very dusty or dirty conditions, the boom pads
will wear much faster. The pads that are under the most
stress from the weight of the load will also wear faster than
other pads. For example, the lower pads at the front of the
boom are under far more stress than the pads attached to
the top, rear or sides of the boom. Consequently the lower
pads will require service more often.

Page 84 8042 Rev 3/04

E. Wear Pad Replacement Replacement of boom wear pads must be performed by an
(As Wear Pad Indicators Indicate) authorized Sky Trak distributor when the wear pads
Each boom pad is manufactured with a convenient wear indicate.
pad indicator. This is the angled cut at each end of all IMPORTANT: The boom has been factory lubricated for
wear pads (Figure 52). The total thickness of a new wear proper wear pad break-in and will normally not require
pad is .625" (15,9 mm). The angled cut will provide a total further lubrication. However, after replacing any wear
wear thickness of .25" (6,4 mm). This will leave approxi- pad(s) or after prolonged periods of inoperation, light
mately .375" (9,5 mm) of total unused material. lubricating with “LPS-3” (or equivalent) of the boom wear
surfaces is recommended to keep the wear pads and boom
The pads must never be worn past the angled cut indicator
wear surfaces lubricated properly. Light lubricating of the
because the metal pad insert that holds the pads in place
boom wear surfaces is also recommended in salt air
will begin to wear into the boom pad sliding surfaces. If
climates or when the vehicle is to be put in storage to
pads are worn past this point it will cause gouging on boom
prevent rusting.
plate surfaces. This will result in premature wear of any
new wear pads installed if the surfaces are not ground ANGLED CUT METAL PAD
smooth again. WEAR PAD INSERT WEAR
INDICATOR PAD

.625" .25"
(15,9 MM) (6,4 MM)

WEAR PAD
SPACER BOOM
PLATE
Figure 52 SC00301

8042 Rev 3/04 Page 85

E. Wear Pad Replacement Replacement of boom wear pads must be performed by an

(As Wear Pad Indicators Indicate) authorized Sky Trak distributor when the wear pads
Each boom pad is manufactured with a convenient wear indicate.
pad indicator. This is the angled cut at each end of all IMPORTANT: The boom has been factory lubricated for
wear pads (Figure 52). The total thickness of a new wear proper wear pad break-in and will normally not require
pad is .625" (15,9 mm). The angled cut will provide a total further lubrication. However, after replacing any wear
wear thickness of .25" (6,4 mm). This will leave approxi- pad(s) or after prolonged periods of inoperation, light
mately .375" (9,5 mm) of total unused material. lubricating with “LPS-3” (or equivalent) of the boom wear
surfaces is recommended to keep the wear pads and boom
The pads must never be worn past the angled cut indicator
wear surfaces lubricated properly. Light lubricating of the
because the metal pad insert that holds the pads in place
boom wear surfaces is also recommended in salt air
will begin to wear into the boom pad sliding surfaces. If
climates or when the vehicle is to be put in storage to
pads are worn past this point it will cause gouging on boom
prevent rusting.
plate surfaces. This will result in premature wear of any
new wear pads installed if the surfaces are not ground ANGLED CUT METAL PAD
smooth again. WEAR PAD INSERT WEAR
INDICATOR PAD

.625" .25"
(15,9 MM) (6,4 MM)

WEAR PAD
SPACER BOOM
PLATE
Figure 52 SC00301

8042 Rev 3/04 Page 85

 15. Emergency Boom Lowering A. In Case of Loss of Engine Power or Hydraulic
Pump Failure:
This section discusses emergency boom lowering proce-
dures:
In any event, the vehicle should be secured until the
Section "A" In case of loss of engine power or hydraulic
situation has been properly evaluated. Secure the vehicle
pump failure.
by following the procedures below.
Section "B" In case of hydraulic line failure.
IMPORTANT: The following instructions are intended to 1. Clear the area around the vehicle of all personnel.
serve as a guideline only. Many different factors may 2. Block all four wheels.
play an important role in this procedure. It is impossible to
cover each and every combination that may be encoun- 3. Section off a large area under the boom with string or
tered. Consult your local Sky Trak Distributor or the JLG tape to restrict any personnel from entering this
Service Department if you are unsure about any part of this potentially dangerous area.
procedure or for any specific instructions for your particular
situation.
WARNING
DO NOT get under a raised boom unless the boom is
blocked up. Always block the boom before doing any
servicing which requires the boom to be up.

Page 86 8042 Rev 3/04

15. Emergency Boom Lowering A. In Case of Loss of Engine Power or Hydraulic

Pump Failure:
This section discusses emergency boom lowering proce-
dures:
In any event, the vehicle should be secured until the
Section "A" In case of loss of engine power or hydraulic
situation has been properly evaluated. Secure the vehicle
pump failure.
by following the procedures below.
Section "B" In case of hydraulic line failure.
IMPORTANT: The following instructions are intended to 1. Clear the area around the vehicle of all personnel.
serve as a guideline only. Many different factors may 2. Block all four wheels.
play an important role in this procedure. It is impossible to
cover each and every combination that may be encoun- 3. Section off a large area under the boom with string or
tered. Consult your local Sky Trak Distributor or the JLG tape to restrict any personnel from entering this
Service Department if you are unsure about any part of this potentially dangerous area.
procedure or for any specific instructions for your particular
situation.
WARNING
DO NOT get under a raised boom unless the boom is
blocked up. Always block the boom before doing any
servicing which requires the boom to be up.

Page 86 8042 Rev 3/04

IMPORTANT: In the event of total loss of engine power or
B. In Case of Hydraulic Line Failure:
hydraulic pump failure with an elevated load, the situation
must be properly evaluated and dealt with on an individual
basis. Contact your local Sky Trak distributor or the JLG
service department at (877) 554-5438 or (717) 485-6657 for
specific instructions for your particular situation. WARNING
4. Temporarily block up or support the outer boom so it In the event of a hydraulic line failure in any of the boom
cannot be lowered. control circuits, extreme CAUTION must be taken
when attempting to lower an elevated boom. Hydraulic
5. If the load is in a position where it can be removed oil under high pressure will escape through the fault in
safely, completely remove the load from the carriage the line which may result in the boom lowering at a rapid
and/or attachment, otherwise leave the load in place. rate. DO NOT perform this procedure unless you are
6. Place a tag on both the ignition switch and steering absolutely sure of what you are doing. Consult your
wheel stating that the vehicle should not be operated. local Sky Trak Distributor or the JLG Service Depart-
If you do not have a tag, tape over the ignition ment before proceeding if you are uncertain about any
switch. of the following procedures.

8042 Rev 3/04 Page 87

IMPORTANT: In the event of total loss of engine power or

B. In Case of Hydraulic Line Failure:
hydraulic pump failure with an elevated load, the situation
must be properly evaluated and dealt with on an individual
basis. Contact your local Sky Trak distributor or the JLG
service department at (877) 554-5438 or (717) 485-6657 for
specific instructions for your particular situation. WARNING
4. Temporarily block up or support the outer boom so it In the event of a hydraulic line failure in any of the boom
cannot be lowered. control circuits, extreme CAUTION must be taken
when attempting to lower an elevated boom. Hydraulic
5. If the load is in a position where it can be removed oil under high pressure will escape through the fault in
safely, completely remove the load from the carriage the line which may result in the boom lowering at a rapid
and/or attachment, otherwise leave the load in place. rate. DO NOT perform this procedure unless you are
6. Place a tag on both the ignition switch and steering absolutely sure of what you are doing. Consult your
wheel stating that the vehicle should not be operated. local Sky Trak Distributor or the JLG Service Depart-
If you do not have a tag, tape over the ignition ment before proceeding if you are uncertain about any
switch. of the following procedures.

8042 Rev 3/04 Page 87

 If line failure is in the Raise or
Lower lines

1. Block or support the boom so it cannot be lowered.

WARNING
Wear protective clothing and proper eye protection when
IMPORTANT: Remove the load completely from the forks working with or around hydraulic oil. Wait for hydraulic oil
and/or attachment by using whatever additional equipment to cool before attempting to repair the failure. Hot hydraulic
may be required for your particular situation. oil can cause severe burns and other serious injury.
2. If the boom has been extended, retract the boom
before proceeding. Boom retraction can be per- a. Locate the fault in the line and use a container
formed by operating the boom retract control lever to catch any oil that escapes. Transfer the oil
in the normal fashion. to a container with a cover and label the
container as used oil. Dispose of the used oil
at an approved recycling center.
3. If the vehicle is not in a potentially hazardous
location, and the boom does not need to be b. (Using two people to perform this procedure will
lowered immediately. Shut off the engine, find the make boom lowering much easier). Remove
line that failed and replace that line. After the the blocking from under the boom. At the base
failure is fixed, remove the blocking, lower the end of each hoist cylinder, locate the counter-
boom, check the oil level and add as necessary. balance valve cartridges (Figure 53). Loosen
Start the engine and bleed the air from the system, the retainer nut and control the rate of boom
then recheck the oil level. The vehicle can now be lowering by turning the adjusting screw on each
put back into service. cartridge simultaneously into the cartridge very
slowly (clockwise). Hydraulic oil from inside
4. If the vehicle is in a potentially hazardous location
the hoist cylinders will escape through the fault
that would require the boom to be lowered immedi-
in the line.
ately and if the line failure is in the boom raise line,
(if in the lowering line, continue with step 5) the
boom must be lowered by following this procedure:

Page 88 8042 Rev 3/04

If line failure is in the Raise or

Lower lines

1. Block or support the boom so it cannot be lowered.

WARNING
Wear protective clothing and proper eye protection when
IMPORTANT: Remove the load completely from the forks working with or around hydraulic oil. Wait for hydraulic oil
and/or attachment by using whatever additional equipment to cool before attempting to repair the failure. Hot hydraulic
may be required for your particular situation. oil can cause severe burns and other serious injury.
2. If the boom has been extended, retract the boom
before proceeding. Boom retraction can be per- a. Locate the fault in the line and use a container
formed by operating the boom retract control lever to catch any oil that escapes. Transfer the oil
in the normal fashion. to a container with a cover and label the
container as used oil. Dispose of the used oil
at an approved recycling center.
3. If the vehicle is not in a potentially hazardous
location, and the boom does not need to be b. (Using two people to perform this procedure will
lowered immediately. Shut off the engine, find the make boom lowering much easier). Remove
line that failed and replace that line. After the the blocking from under the boom. At the base
failure is fixed, remove the blocking, lower the end of each hoist cylinder, locate the counter-
boom, check the oil level and add as necessary. balance valve cartridges (Figure 53). Loosen
Start the engine and bleed the air from the system, the retainer nut and control the rate of boom
then recheck the oil level. The vehicle can now be lowering by turning the adjusting screw on each
put back into service. cartridge simultaneously into the cartridge very
slowly (clockwise). Hydraulic oil from inside
4. If the vehicle is in a potentially hazardous location
the hoist cylinders will escape through the fault
that would require the boom to be lowered immedi-
in the line.
ately and if the line failure is in the boom raise line,
(if in the lowering line, continue with step 5) the
boom must be lowered by following this procedure:

Page 88 8042 Rev 3/04

IMPORTANT: By turning the counterbalance cartridge a. (Using two people to perform this procedure
adjusting screws in to make the valve inoperative, the will make boom lowering much easier) At the
pressure settings of the cartridge have been altered and base end of each hoist cylinder, locate the
the valve has lost its load holding ability. DO NOT attempt counterbalance valve cartridges (Figure 53).
to reset these cartridges. By attempting to reset these Loosen the retainer nut on each cartridge and
cartridges it will more than likely result in erratic (extreme turn the adjusting screws in (clockwise) until
bouncing or racking at ends of cylinder stroke) lowering they bottom out. Doing this will render each
action, which may cause damage to other components. counterbalance valve inoperative.
Remove and discard both cartridges and replace with new
parts.

BOOM HOIST

WARNING CYLINDERS

Wear protective clothing and proper eye protection when

working with or around hydraulic oil. Wait for hydraulic oil
to cool before attempting to repair the failure. Hot hydraulic COUNTERBALANCE
oil can cause severe burns and other serious injury. VALVE

5. If the vehicle is in a potentially hazardous location

that would require the boom to be lowered immedi-
ately and if the line failure is in the boom lowering
line, the boom must be lowered by following the
next 4 steps.
ADJUSTING
SCREW
RETAINER NUT
Figure 53 OH0210

8042 Rev 3/04 Page 89

IMPORTANT: By turning the counterbalance cartridge a. (Using two people to perform this procedure
adjusting screws in to make the valve inoperative, the will make boom lowering much easier) At the
pressure settings of the cartridge have been altered and base end of each hoist cylinder, locate the
the valve has lost its load holding ability. DO NOT attempt counterbalance valve cartridges (Figure 53).
to reset these cartridges. By attempting to reset these Loosen the retainer nut on each cartridge and
cartridges it will more than likely result in erratic (extreme turn the adjusting screws in (clockwise) until
bouncing or racking at ends of cylinder stroke) lowering they bottom out. Doing this will render each
action, which may cause damage to other components. counterbalance valve inoperative.
Remove and discard both cartridges and replace with new
parts.

BOOM HOIST

WARNING CYLINDERS

Wear protective clothing and proper eye protection when

working with or around hydraulic oil. Wait for hydraulic oil
to cool before attempting to repair the failure. Hot hydraulic COUNTERBALANCE
oil can cause severe burns and other serious injury. VALVE

5. If the vehicle is in a potentially hazardous location

that would require the boom to be lowered immedi-
ately and if the line failure is in the boom lowering
line, the boom must be lowered by following the
next 4 steps.
ADJUSTING
SCREW
RETAINER NUT
Figure 53 OH0210

8042 Rev 3/04 Page 89

IMPORTANT: By turning the counterbalance cartridge If line failure is in the Extend or
adjusting screws in to make the valve inoperative, the Retract lines
pressure settings of the cartridge have been altered and the
valve has lost its load holding ability. DO NOT attempt to
reset these cartridges. By attempting to reset these
cartridges it will more than likely result in erratic (extreme
bouncing or racking at ends of cylinder stroke) lowering
WARNING
action, which may cause damage to other components. DO NOT get under a raised boom unless the boom is
Remove and discard both cartridges and replace with new blocked up. Always block the boom before doing any
parts. servicing which requires the boom to be up.

b. Locate the fault in the line and use a container IMPORTANT: If the boom has been extended, you
to catch any oil that escapes. Transfer the oil must first remove the load from the forks and/or attach-
to a container with a cover and label the ment before you attempt to lower the boom.
container as used oil. Dispose of the used oil 1. Temporarily block or support the boom so it cannot
at an approved recycling center. be lowered.
c. Remove the blocking from under the boom. IMPORTANT: Remove the load completely from the forks
Clear the area around the vehicle of all person- and/or attachment by using whatever additional equipment
nel and return to the operator's cab. may be required for your particular situation.
2. If the vehicle is not in a potentially hazardous
d. With the engine OFF, move the boom control
location, and the boom does not need to be
lever forward to lower the boom. Oil will
retracted immediately. Shut off the engine, find the
escape through the fault in the line.
line that failed and replace that line. After the
failure is fixed, remove the blocking, retract and
6. Replace the failed hydraulic line. Check the oil lower the boom, recheck the oil level and add as
level and add as necessary. Bleed the air from the necessary. Start the engine and bleed the air from
system and then recheck the oil level. the system, then recheck the oil level. The vehicle
can now be put back into service.

Page 90 8042 Rev 3/04

IMPORTANT: By turning the counterbalance cartridge If line failure is in the Extend or

adjusting screws in to make the valve inoperative, the Retract lines
pressure settings of the cartridge have been altered and the
valve has lost its load holding ability. DO NOT attempt to
reset these cartridges. By attempting to reset these
cartridges it will more than likely result in erratic (extreme
bouncing or racking at ends of cylinder stroke) lowering
WARNING
action, which may cause damage to other components. DO NOT get under a raised boom unless the boom is
Remove and discard both cartridges and replace with new blocked up. Always block the boom before doing any
parts. servicing which requires the boom to be up.

b. Locate the fault in the line and use a container IMPORTANT: If the boom has been extended, you
to catch any oil that escapes. Transfer the oil must first remove the load from the forks and/or attach-
to a container with a cover and label the ment before you attempt to lower the boom.
container as used oil. Dispose of the used oil 1. Temporarily block or support the boom so it cannot
at an approved recycling center. be lowered.
c. Remove the blocking from under the boom. IMPORTANT: Remove the load completely from the forks
Clear the area around the vehicle of all person- and/or attachment by using whatever additional equipment
nel and return to the operator's cab. may be required for your particular situation.
2. If the vehicle is not in a potentially hazardous
d. With the engine OFF, move the boom control
location, and the boom does not need to be
lever forward to lower the boom. Oil will
retracted immediately. Shut off the engine, find the
escape through the fault in the line.
line that failed and replace that line. After the
failure is fixed, remove the blocking, retract and
6. Replace the failed hydraulic line. Check the oil lower the boom, recheck the oil level and add as
level and add as necessary. Bleed the air from the necessary. Start the engine and bleed the air from
system and then recheck the oil level. the system, then recheck the oil level. The vehicle
can now be put back into service.

Page 90 8042 Rev 3/04

 3. If the vehicle is in a potentially hazardous location Reassemble a new extend line. After the
that would require the boom to be retracted imme- failure is fixed, remove the blocking, retract
diately. Shut off the engine and refer to Figure 54 and lower the boom, check the oil level and
to identify the failed hose. Use step “a” if the add as necessary. Start the engine and bleed
failure is in the retract line or step “b” if the failure the air from the system, then recheck the oil
is in the extend line. If the failure is in either the level. The vehicle can now be put back into
extend or retract tubes (Figure 54) contact your service.
local Sky Trak distributor for repair parts or contact
the JLG service department for specific instruc-
tions. EXTEND LINE

RETRACT LINE
RETRACT LINE (Figure 54)
a. Locate the failed retract hose and remove the
RETRACT
hose. In the same area locate the extend TUBE
hose and remove it from the circuit. Replace
the failed retract hose with the extend hose.
Place a container under the extend port on the
cylinder to catch any oil that will escape during EXTEND TUBE
boom retraction. Return to the operators cab, RETRACT LINE
start the engine and slowly retract the boom.
Stop the engine.
EXTEND LINE
Transfer the oil to a container with a cover and
label the container as used oil. Dispose of the
used oil at an approved recycling center.
CONTROL VALVE
(ROTATED FOR CLARITY)

Figure 54 OH1120

8042 Rev 3/04 Page 91

3. If the vehicle is in a potentially hazardous location Reassemble a new extend line. After the
that would require the boom to be retracted imme- failure is fixed, remove the blocking, retract
diately. Shut off the engine and refer to Figure 54 and lower the boom, check the oil level and
to identify the failed hose. Use step “a” if the add as necessary. Start the engine and bleed
failure is in the retract line or step “b” if the failure the air from the system, then recheck the oil
is in the extend line. If the failure is in either the level. The vehicle can now be put back into
extend or retract tubes (Figure 54) contact your service.
local Sky Trak distributor for repair parts or contact
the JLG service department for specific instruc-
tions. EXTEND LINE

RETRACT LINE
RETRACT LINE (Figure 54)
a. Locate the failed retract hose and remove the
RETRACT
hose. In the same area locate the extend TUBE
hose and remove it from the circuit. Replace
the failed retract hose with the extend hose.
Place a container under the extend port on the
cylinder to catch any oil that will escape during EXTEND TUBE
boom retraction. Return to the operators cab, RETRACT LINE
start the engine and slowly retract the boom.
Stop the engine.
EXTEND LINE
Transfer the oil to a container with a cover and
label the container as used oil. Dispose of the
used oil at an approved recycling center.
CONTROL VALVE
(ROTATED FOR CLARITY)

Figure 54 OH1120

8042 Rev 3/04 Page 91

 EXTEND LINE (Figure 55)
EXTEND LINE
b. Place a container under the failure in the
RETRACT LINE
extend line to catch any oil that will escape
during boom retraction. Return to the opera-
tors cab, start the engine and slowly retract RETRACT
the boom. Stop the engine. TUBE

Transfer the oil to a container with a cover and

label the container as used oil. Dispose of the
used oil at an approved recycling center. EXTEND TUBE
RETRACT LINE
Replace the failed extend line. After the failure
is fixed, remove the blocking, retract and lower
the boom, check the oil level and add as EXTEND LINE
necessary. Start the engine and bleed the air
from the system, then recheck the oil level.
The vehicle can now be put back into service.
CONTROL VALVE
(ROTATED FOR CLARITY)

Figure 55 OH1120

Page 92 8042 Rev 3/04

EXTEND LINE (Figure 55)

EXTEND LINE
b. Place a container under the failure in the
RETRACT LINE
extend line to catch any oil that will escape
during boom retraction. Return to the opera-
tors cab, start the engine and slowly retract RETRACT
the boom. Stop the engine. TUBE

Transfer the oil to a container with a cover and

label the container as used oil. Dispose of the
used oil at an approved recycling center. EXTEND TUBE
RETRACT LINE
Replace the failed extend line. After the failure
is fixed, remove the blocking, retract and lower
the boom, check the oil level and add as EXTEND LINE
necessary. Start the engine and bleed the air
from the system, then recheck the oil level.
The vehicle can now be put back into service.
CONTROL VALVE
(ROTATED FOR CLARITY)

Figure 55 OH1120

Page 92 8042 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 operating
temperature;
• Apply the service brake;
• Place the travel select lever in (F) FORWARD and
the transmission in (1) first gear;
• Disengage the emergency brake, release service
brake, and drive machine to an open area with a
firm level surface, free of obstacles; and
• Move the unit slowly (approximately 1 mph
[1,6 kph]) in a forward direction and engage the
emergency brake. Ensure the emergency brake
system stops the unit abruptly.

8042 Rev 3/04 Page 93

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 operating
temperature;
• Apply the service brake;
• Place the travel select lever in (F) FORWARD and
the transmission in (1) first gear;
• Disengage the emergency brake, release service
brake, and drive machine to an open area with a
firm level surface, free of obstacles; and
• Move the unit slowly (approximately 1 mph
[1,6 kph]) in a forward direction and engage the
emergency brake. Ensure the emergency brake
system stops the unit abruptly.

8042 Rev 3/04 Page 93

Specifications HYDRAULIC SYSTEM
Capacity - System ................................. 53 gals. (200,6 ltr)
Capacity - Reservoir ............................ 30.3 gals. (114,7 ltr)
Fluid and Lubricant Capacities Type of Oil ................ MIL-L-2104C, 10W or ISO Grade 46
ENGINE CRANKCASE OIL (see table on page 67)
Capacity with filter change
Cummins Turbo ..................................... 11.6 qts. (11 ltr) TRANSMISSION
Filter ......................................................... 1.5 qts. (1,4 ltr) Capacity with filter change ........................ 4.5 gals. (17 ltr)
Type of Oil - Below 23° F (-5° C) ............................. 10W30 Type of Fluid ............................................ 10W30 Motor Oil
Above 23° F (-5° C) ............................ 15W40 (see table on page 70 for other approved lubricants)
equal to API, CD or CE specs.
AXLES
FUEL TANK Differential Housing Capacity ....................... 18 qts. (17 ltr)
Capacity ............................................. 35.5 gals. (134,4 ltr) Type of Lubricant -
Usable ................................................ 33.5 gals. (126,8 ltr) Above -15° F (-26° C) ........................... 80W 90 Gear Oil
Type of Fuel above 32° F (0° C) ........... Standard #2 Diesel Below -15° F (-26° C) ...................................... 75W Gear
Type of Fuel below 32° F (0° C) ......... Winterized #2 Diesel
Wheel End Capacity - each (front) .............. 54 ozs. (1,6 ltr)
COOLING SYSTEM Wheel End Capacity - each (rear) ............... 54 ozs. (1,6 ltr)
Capacity - System (w/o heater) ................. 4 gals. (15,1 ltr) (see table on page 74)
Capacity - Overflow Bottle ........................... 3 qts. (2,8 ltr)
Type of Fluid ..................... 50/50 ethylene glycol and water

Page 94 8042 Rev 3/04

Specifications HYDRAULIC SYSTEM

Capacity - System ................................. 53 gals. (200,6 ltr)
Capacity - Reservoir ............................ 30.3 gals. (114,7 ltr)
Fluid and Lubricant Capacities Type of Oil ................ MIL-L-2104C, 10W or ISO Grade 46
ENGINE CRANKCASE OIL (see table on page 67)
Capacity with filter change
Cummins Turbo ..................................... 11.6 qts. (11 ltr) TRANSMISSION
Filter ......................................................... 1.5 qts. (1,4 ltr) Capacity with filter change ........................ 4.5 gals. (17 ltr)
Type of Oil - Below 23° F (-5° C) ............................. 10W30 Type of Fluid ............................................ 10W30 Motor Oil
Above 23° F (-5° C) ............................ 15W40 (see table on page 70 for other approved lubricants)
equal to API, CD or CE specs.
AXLES
FUEL TANK Differential Housing Capacity ....................... 18 qts. (17 ltr)
Capacity ............................................. 35.5 gals. (134,4 ltr) Type of Lubricant -
Usable ................................................ 33.5 gals. (126,8 ltr) Above -15° F (-26° C) ........................... 80W 90 Gear Oil
Type of Fuel above 32° F (0° C) ........... Standard #2 Diesel Below -15° F (-26° C) ...................................... 75W Gear
Type of Fuel below 32° F (0° C) ......... Winterized #2 Diesel
Wheel End Capacity - each (front) .............. 54 ozs. (1,6 ltr)
COOLING SYSTEM Wheel End Capacity - each (rear) ............... 54 ozs. (1,6 ltr)
Capacity - System (w/o heater) ................. 4 gals. (15,1 ltr) (see table on page 74)
Capacity - Overflow Bottle ........................... 3 qts. (2,8 ltr)
Type of Fluid ..................... 50/50 ethylene glycol and water

Page 94 8042 Rev 3/04

 WHEEL NUT TORQUE ....... 450 - 500 lb-ft (610 - 680 Nm)
Tires
AIR PRESSURES MAXIMUM GROUND PRESSURE (w/full load)
13.00 - 24, 12 ply ..................................... 70 psi (482 kPa) 13.00 - 24 or R24 Size Tires ............... 105 psi (723 kPa)
13.00 R24, Radial (One Star) ................... 80 psi (551 kPa) 15.5 - 25 Size Tires .............................. 74 psi (510 kPa)
15.5 - 25, 12 ply ....................................... 58 psi (400 kPa)
MINIMUM WEIGHT OF EACH TIRE AND WHEEL
ASSEMBLY WITH BALLAST
HYDROFILL MIXTURE 13.00 - 24, 12 ply ..................................... 704 lbs. (319 kg)
13.00 - 24, 12 ply .................. 164 lbs. (74,4 kg) Calcium 13.00 - 24, 14 ply ..................................... 716 lbs. (325 kg)
Chloride to 33 gals. (124,9 ltr) of Water (each tire) 13.00 R24, Radial (One Star) ................... 740 lbs. (336 kg)
Total Hydrofill weight (each tire) ...... 438 lbs. (198,7 kg) 15.5 - 25, 12 ply ....................................... 839 lbs. (381 kg)
13.00 R24, Radial .................. 164 lbs. (74,4 kg) Calcium
Chloride to 33 gals. (124,9 ltr) of Water (each tire) IMPORTANT: If any other type of ballast is added, the total
Total Hydrofill weight (each tire) ...... 438 lbs. (198,7 kg) weight of the tire and wheel assembly, including ballast
15.5 - 25, 12 ply .................... 187 lbs. (85,8 kg) Calcium Must Not Be Less Than the minimum assembly weight
Chloride to 37 gals. (140 ltr) of Water (each tire) listed above.
Total Hydrofill weight (each tire) ...... 500 lbs. (226,8 kg)

NOTE: Tires (bias or radial) are not to be filled with

water only.
NOTE: For other types of ballast used with these tires
consult the factory.

8042 Rev 3/04 Page 95

WHEEL NUT TORQUE ....... 450 - 500 lb-ft (610 - 680 Nm)
Tires
AIR PRESSURES MAXIMUM GROUND PRESSURE (w/full load)
13.00 - 24, 12 ply ..................................... 70 psi (482 kPa) 13.00 - 24 or R24 Size Tires ............... 105 psi (723 kPa)
13.00 R24, Radial (One Star) ................... 80 psi (551 kPa) 15.5 - 25 Size Tires .............................. 74 psi (510 kPa)
15.5 - 25, 12 ply ....................................... 58 psi (400 kPa)
MINIMUM WEIGHT OF EACH TIRE AND WHEEL
ASSEMBLY WITH BALLAST
HYDROFILL MIXTURE 13.00 - 24, 12 ply ..................................... 704 lbs. (319 kg)
13.00 - 24, 12 ply .................. 164 lbs. (74,4 kg) Calcium 13.00 - 24, 14 ply ..................................... 716 lbs. (325 kg)
Chloride to 33 gals. (124,9 ltr) of Water (each tire) 13.00 R24, Radial (One Star) ................... 740 lbs. (336 kg)
Total Hydrofill weight (each tire) ...... 438 lbs. (198,7 kg) 15.5 - 25, 12 ply ....................................... 839 lbs. (381 kg)
13.00 R24, Radial .................. 164 lbs. (74,4 kg) Calcium
Chloride to 33 gals. (124,9 ltr) of Water (each tire) IMPORTANT: If any other type of ballast is added, the total
Total Hydrofill weight (each tire) ...... 438 lbs. (198,7 kg) weight of the tire and wheel assembly, including ballast
15.5 - 25, 12 ply .................... 187 lbs. (85,8 kg) Calcium Must Not Be Less Than the minimum assembly weight
Chloride to 37 gals. (140 ltr) of Water (each tire) listed above.
Total Hydrofill weight (each tire) ...... 500 lbs. (226,8 kg)

NOTE: Tires (bias or radial) are not to be filled with

water only.
NOTE: For other types of ballast used with these tires
consult the factory.

8042 Rev 3/04 Page 95

 Engine Electrical System
Make and Model .................................. Cummins 4BT3.9 RATING. ..................................... 12 VDC Negative Ground
Turbo Charged Diesel NUMBER & TYPE OF BATTERIES. ............................... 1
Horsepower ..................................... 110 hp @ 2500 rpm Maintenance Free
Low Engine Idle ........................................ 1050± 50 rpm FUSE RATINGS
Rear Stabilizer Solenoids ...................................... 7.5 amp
Weights Steering Select Switch and Valve ......................... 7.5 amp
Horn and Back-up Alarm (Optional - Heater Fan) .... 10 amp
BASIC VEHICLE
Warning lights, Emergency Brake Solenoid Switch,
*Approximate Curb Weight .............. 23,840 lbs (10823 kg)
Fuel Gauge and Hourmeter ................................. 10 amp
Shipping Weight .............................. 23,630 lbs (10719 kg)
Ignition Switch Feed for Entire Electrical System ... 40 amp
*With open cab, 13.00 - 24 hydrofilled tires and full fuel
(Optional - Light Switch Relay) .............................. 7.5 amp
tank
(Optional - Enclosed Cab) ...................................... 10 amp
OPERATING LOAD. ............................ 8,000 lbs (3629 kg)
(Optional - Lighting Package) ................................. 20 amp
RELAY RATINGS
Vehicle Dimensions Boom Switch ................................................... 12V 40 amp
With 13.00 - 24 Tires Stabilizer Lock ................................................ 12V 40 amp
Length (less forks) ............................. 221.3" (5621 mm) Back-up Alarm ................................................ 12V 40 amp
Width ................................................... 96.4" (2448 mm) Neutral Start .................................................... 12V 40 amp
Height ................................................ 100.5" (2553 mm) Emergency Brake Disconnect ......................... 12V 40 amp
Wheelbase ......................................... 119.5" (3035 mm) (Optional - Light Switch) .................................. 12V 30 amp
Ground Clearance .................................. 16.3" (412 mm)
Tread ................................................... 81.8" (2077 mm)
Turning Clearance Radius ......................... 14' 8" (4,5 m)
Max. Reach from Front
Tires to 24" load center .............................. 26' 8"(8,1 m)

Page 96 8042 Rev 3/04

Engine Electrical System

Make and Model .................................. Cummins 4BT3.9 RATING. ..................................... 12 VDC Negative Ground
Turbo Charged Diesel NUMBER & TYPE OF BATTERIES. ............................... 1
Horsepower ..................................... 110 hp @ 2500 rpm Maintenance Free
Low Engine Idle ........................................ 1050± 50 rpm FUSE RATINGS
Rear Stabilizer Solenoids ...................................... 7.5 amp
Weights Steering Select Switch and Valve ......................... 7.5 amp
Horn and Back-up Alarm (Optional - Heater Fan) .... 10 amp
BASIC VEHICLE
Warning lights, Emergency Brake Solenoid Switch,
*Approximate Curb Weight .............. 23,840 lbs (10823 kg)
Fuel Gauge and Hourmeter ................................. 10 amp
Shipping Weight .............................. 23,630 lbs (10719 kg)
Ignition Switch Feed for Entire Electrical System ... 40 amp
*With open cab, 13.00 - 24 hydrofilled tires and full fuel
(Optional - Light Switch Relay) .............................. 7.5 amp
tank
(Optional - Enclosed Cab) ...................................... 10 amp
OPERATING LOAD. ............................ 8,000 lbs (3629 kg)
(Optional - Lighting Package) ................................. 20 amp
RELAY RATINGS
Vehicle Dimensions Boom Switch ................................................... 12V 40 amp
With 13.00 - 24 Tires Stabilizer Lock ................................................ 12V 40 amp
Length (less forks) ............................. 221.3" (5621 mm) Back-up Alarm ................................................ 12V 40 amp
Width ................................................... 96.4" (2448 mm) Neutral Start .................................................... 12V 40 amp
Height ................................................ 100.5" (2553 mm) Emergency Brake Disconnect ......................... 12V 40 amp
Wheelbase ......................................... 119.5" (3035 mm) (Optional - Light Switch) .................................. 12V 30 amp
Ground Clearance .................................. 16.3" (412 mm)
Tread ................................................... 81.8" (2077 mm)
Turning Clearance Radius ......................... 14' 8" (4,5 m)
Max. Reach from Front
Tires to 24" load center .............................. 26' 8"(8,1 m)

Page 96 8042 Rev 3/04

REPLACEMENT BULBS
Headlights/Worklights Position 1
Replacement Bulbs - Hobbs .................................#73214 Longitudinal stability “stacking”
Replacement Bulbs - Speaker .......................... #4830830 (with rated load)
Warning Light Bulbs .................................. Qty. 4 (GE 161)
Brake Light/Turn Signal - Rear ................................. #1157
Turn Signal - Front ................................................... #1156

Stability Tipping Limits

This telescopic handler has been shown to meet or exceed

75
60
30 45
-15 15

ASME, and FEM stability limits in highly structured and

controlled test situations. These stability tipping limits are THIS SIDE UP

extremes and are not intended to be achieved during

normal worksite operation. The following is provided only
as information to the operator of this vehicle and in no way
should be used as a guideline for operating this vehicle.
For safe operation, follow the instructions as provided on
the preceding pages of this manual.

7% GRADE (4°)

OH0130

8042 Rev 3/04 Page 97

REPLACEMENT BULBS
Headlights/Worklights Position 1
Replacement Bulbs - Hobbs .................................#73214 Longitudinal stability “stacking”
Replacement Bulbs - Speaker .......................... #4830830 (with rated load)
Warning Light Bulbs .................................. Qty. 4 (GE 161)
Brake Light/Turn Signal - Rear ................................. #1157
Turn Signal - Front ................................................... #1156

Stability Tipping Limits

This telescopic handler has been shown to meet or exceed

75
60

30 45
-15 15

ASME, and FEM stability limits in highly structured and

controlled test situations. These stability tipping limits are THIS SIDE UP

extremes and are not intended to be achieved during

normal worksite operation. The following is provided only
as information to the operator of this vehicle and in no way
should be used as a guideline for operating this vehicle.
For safe operation, follow the instructions as provided on
the preceding pages of this manual.

7% GRADE (4°)

OH0130

8042 Rev 3/04 Page 97

 Position 2 Position 3
Longitudinal stability “traveling” Lateral stability “stacking”with rated load
(with no more than rated load) (with frame tilted 4°)

75
45 60

30
-15 15

THIS SIDE
UP

22% GRADE (12°) 12% GRADE (7°)

OH0180
OH0140

Page 98 8042 Rev 3/04

Position 2 Position 3
Longitudinal stability “traveling” Lateral stability “stacking”with rated load
(with no more than rated load) (with frame tilted 4°)
75
45 60

30
-15 15

THIS SIDE
UP

22% GRADE (12°) 12% GRADE (7°)

OH0180
OH0140

Page 98 8042 Rev 3/04

 Position 4 Position 5
Lateral stability “traveling” Lateral stability “stacking”
(with no load) (with no load)

-1
5 60

75
30
15 45

50% GRADE (27°) 10% GRADE (6°)

OH0121 OH0151

8042 Rev 3/04 Page 99

Position 4 Position 5
Lateral stability “traveling” Lateral stability “stacking”
(with no load) (with no load)

-1
5 60
75

30
15 45

50% GRADE (27°) 10% GRADE (6°)

OH0121 OH0151

8042 Rev 3/04 Page 99

 Notes
(OR, on this page, affix second copy of attachment
capacity chart if supplied with attachment)

Page 100 8042 Rev 3/04

Notes
(OR, on this page, affix second copy of attachment
capacity chart if supplied with attachment)

Page 100 8042 Rev 3/04

 JLG Industries, Inc. JLG Industries, Inc.
TRANSFER OF OWNERSHIP TRANSFER OF OWNERSHIP
To: JLG, Gradall, Lull and Sky Trak product owner: To: JLG, Gradall, Lull and Sky Trak product owner:
If you now own, but ARE NOT the original purchaser of the product covered If you now own, but ARE NOT the original purchaser of the product covered
by this manual, we would like to know who you are. For the purpose of receiving safe- by this manual, we would like to know who you are. For the purpose of receiving safe-
ty-related bulletins, it is very important to keep JLG Industries, Inc. updated with the ty-related bulletins, it is very important to keep JLG Industries, Inc. updated with the
current ownership of all JLG products. JLG maintains owner information for each JLG current ownership of all JLG products. JLG maintains owner information for each JLG
product and uses this information in cases where owner notification is necessary. product and uses this information in cases where owner notification is necessary.
Please use this form to provide JLG with updated information with regard to Please use this form to provide JLG with updated information with regard to
the current ownership of JLG Products. Please return completed form to the JLG the current ownership of JLG Products. Please return completed form to the JLG
Product Safety & Reliability Department via facsimile (717) 485-6573 or mail to Product Safety & Reliability Department via facsimile (717) 485-6573 or mail to
address as specified on the back of this form. address as specified on the back of this form.
Thank you, Thank you,
Product Safety & Reliability Department Product Safety & Reliability Department
JLG Industries, Inc. JLG Industries, Inc.
1 JLG Drive 1 JLG Drive
McConnellsburg, PA 17233-9533 McConnellsburg, PA 17233-9533
Telephone: (717) 485-5161 Telephone: (717) 485-5161
Fax: (717) 485-6573 Fax: (717) 485-6573

NOTE: Leased or rented units should not be included on this form. NOTE: Leased or rented units should not be included on this form.

Mfg. Model: Mfg. Model:

Serial Number: Serial Number:

Previous Owner: Previous Owner:

Address: Address:

City: State: City: State:

Zip: Telephone: ( ) Zip: Telephone: ( )

Date Of Transfer: Date Of Transfer:

Current Owner: Current Owner:

Address: Address:

City: State: City: State:

Zip: Telephone: ( ) Zip: Telephone: ( )

Who in your organization should we notify? Who in your organization should we notify?

Name: Name:

Title: Title:
 REPLACEMENT MANUALS
If the owner/operator or safety manuals that were originally shipped with your
vehicle are lost, stolen or need replacement, contact your local distributor for
replacement manuals.

If for any reason your distributor cannot supply the manuals you need; write,
call or send a fax to the following address for ordering information.

JLG Industries, Inc.

1 JLG Drive
McConnellsburg, PA 17233-9533 USA

Phone: (877) 554-5438 or (717) 485-6472

Parts 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 Name
3. Model and Serial Number

REPLACEMENT MANUALS
If the owner/operator or safety manuals that were originally shipped with your
vehicle are lost, stolen or need replacement, contact your local distributor for
replacement manuals.

If for any reason your distributor cannot supply the manuals you need; write,
call or send a fax to the following address for ordering information.

JLG Industries, Inc.

1 JLG Drive
McConnellsburg, PA 17233-9533 USA

Phone: (877) 554-5438 or (717) 485-6472

Parts 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 Name
3. Model and Serial Number