Operators and Safety Manual. Model ANSI

Transcription

1 Operators and Safety Manual Model November 1999 ANSI

2 WARNING Improper operation of this vehicle can cause injury or death. Before starting the engine, do the following: 1. Read this owner/operators manual. 2. Read all the safety decals on the vehicle. 3. Clear the area of other persons. Learn and practice safe use of vehicle controls in a safe, clear area before you operate this vehicle on a worksite. It is your responsibility to observe applicable laws and regulations and to follow manufacturer's instructions 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.

3 Introduction The Manual...2 Replacement Parts...2 Reports...2 Safety Practices Disclaimer...3 Hazard Classification System...3 New or Additional Operators...4 Personal Considerations...4 Operational Considerations...8 Equipment Considerations...13 Operation Operator Controls...18 Operators Display Panel...31 Instruments and Indicators...36 Optional Controls...38 Pre-Operation Inspection...43 Normal Starting...44 Cold Starting (Perkins)...45 Cold Starting (Cummins)...47 Jump Starting...50 Refueling...51 Operating...53 Using the Capacity Chart...68 Fork Rating...75 How To Pick, Carry & Place A Load...76 Elevating Personnel...76 Using Other Attachments...78 Shut-Off...79 Emergency Operations Towing a Disabled Vehicle...83 Emergency Boom Lowering...87 Table of Contents General Maintenance Introduction Maintenance Schedule & Checklist Lubrication Points Air Cleaner Opt. Closed Cab Air Filters Engine Cooling System Engine Oil and Filter Engine Fuel System Engine Fan Belt Hydraulic Oil and Filter Transmission Oil and Filter Axle Oil Wheel End Oil Transfer Case Oil Wheels and Tires Battery Fuse & Relay Replacement Boom Chains & Wear Pads Storage Transport Specifications Fluid & Lubrication Capacities Tires Weights Vehicle Dimensions Electrical System Engine

4 Introduction Introduction The Manual This Owners/Operators Manual provides the information you need to correctly operate and maintain this vehicle. IMPORTANT! Before you operate this vehicle, read this manual completely and carefully so you will understand the instructions and the proper operation of the controls and equipment. You must comply with all Danger, Warning, and Caution notices; they are for your benefit. All references to the right side, left side, front, or rear are given from the operator's seat looking forward. Sky Trak International is hereinafter referred to as Sky Trak. For easy reference when ordering replacement parts or making service inquiries on this vehicle, record its model and serial number on the back cover of this manual. The serial number and work order number are stamped into the serial number plate which is located on the front of the vehicle s frame. Replacement Parts Serial Number Plate OS0013 IMPORTANT! The replacement of any part on this vehicle by anything other than a Sky Trak authorized replacement part may adversely affect the performance, durability or safety of this vehicle and may void the warranty. Sky Trak assumes no liability for unauthorized replacement parts which adversely affect the performance, durability or safety of this vehicle. Reports IMPORTANT! A Warranty Registration form must be filled out by the Sky Trak distributor, signed by the purchaser, and returned to Sky Trak once the product is sold and/or put into service. This report activates the warranty period, assuring that your claims during the warranty period will be processed promptly. To guarantee full warranty service, make sure your distributor has returned the business reply card of this form to Sky Trak Rev 11/99

5 Safety Practices Disclaimer Sky Trak reserves the right to make changes on and to add improvements upon its products at any time without public notice or obligation. Sky Trak also reserves the right to discontinue manufacturing any product at its discretion at any time. The information in this manual does not replace any safety rules and laws used in your area. Before operating this vehicle, learn the rules and laws for your area. Make sure the vehicle has the correct equipment according to these rules and laws. Your safety and the safety of others in the worksite depend significantly upon your knowlege and understanding of all correct operating practices and procedures for this vehicle. WARNING DO NOT modify or alter (weld, drill, etc.) any part of this vehicle without consulting Sky Trak. Modifications can weaken the structure creating a hazard that can cause injury or death. Safety Practices Hazard Classification System OP0330 This safety alert symbol is used with the following signal words to attract your attention to messages found within the manual and on safety decals located on the vehicle. They are reproduced herein and pertain to proper operation and procedure messages contained throughout the manual. The message that follows the symbol contains important information about Safety. To avoid possible injury or death, carefully read and follow the messages! Be sure to fully understand the potential causes of injury or death. Signal Word: A distinctive word used throughout this manual that alerts the reader to the existence and relative degree of the hazard on or near the vehicle Rev 11/99 3

6 Safety Practices ON0021 The signal word DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. ON0030 The signal word WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. ON0010 The signal word CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. OS2020 The signal word CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage 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 or rented to someone other than the purchaser, make certain that the new operator reads and understands this Operators Manual before operating the vehicle. In addition, make sure that the new operator has completed 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. 1. Seat Belt New or Additional Operators Personal Considerations Always fasten the seat belt before starting the engine Rev 11/99

7 2. Clothing and Safety Gear Safety Practices DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts. Wear protective clothing and personal safety gear issued or called for by job conditions. 3. Dismounting OS0023 DO NOT get off the vehicle until you: level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, engage the parking brake switch, turn the engine off, if appropriate, unbuckle the seat belt, exit the vehicle using the hand holds. 4. Chemical Hazards A. Exhaust Fumes Fumes from the engine exhaust can cause injury or death. DO NOT operate vehicle in an enclosed area without a ventilation system capable of routing the hazardous fumes outdoors. B. Explosive Fuel Engine fuel is flammable and can cause a fire and/or an explosion. Avoid danger by keeping sparks, open flames and smoking materials away from the vehicle and from fuel during refueling or when servicing the fuel system. Know where fire extinguishers are kept on the worksite and how to use them Rev 11/99 5

8 Safety Practices C. Hydraulic Fluid 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 injuries or death. HOT HYDRAULIC FLUID WILL CAUSE SEVERE BURNS. Wait for fluid to cool down before disconnecting lines. DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid. Hydraulic fluid can cause permanent eye injury. Wear appropriate eye protection and stop engine and relieve pressure before disconnecting lines. If anyone is injured by or if any hydraulic fluid is injected into the skin, obtain medical attention immediately or gangrene may result. D. Battery The following WARNING is intended to supplement and does not replace the warnings and information provided on the battery by the battery manufacturer. When jump starting the vehicle, carefully follow instructions found under Jump Starting on page OS0621 Keep sparks, flames and lit cigarettes away from the battery at all times. Lead acid batteries generate explosive gases. Severe chemical burns can result from improper handling of battery electrolyte. Wear safety glasses and proper protective gear when handling batteries to prevent electrolyte from coming in contact with eyes, skin or clothing Rev 11/99

9 Safety Practices 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 immediately. IMPORTANT! In case of internal contact, DO NOT give fluids that would induce vomiting! 5. Moving Parts Hazard DO NOT place limbs near moving parts. Severing of any body part can result. Turn off engine and wait until fan and belts stop moving before servicing. 6. Lowering Boom or Falling Load Hazard OS0042 DO NOT get under a raised boom unless it is blocked up safely. Always empty the attachment of any load and block the boom up before doing any servicing that would require the boom to be raised. NEVER allow anyone to walk or stand under the boom. A lowering boom or falling load can result in serious injury or death Rev 11/99 7

10 Safety Practices 1. Preperation and Prevention Know the location and function of all vehicle controls. Make sure all persons are away from the vehicle and that the Travel Select Lever is in the (N) NEUTRAL position with the parking brake switch engaged before starting the engine. Holes, obstructions, debris and other worksite hazards can cause injury or death. Always walk around and look for these and other hazards before operating the vehicle on a new worksite. Prevent accidents when you move the vehicle around the worksite. Know the rules for movement of people and vehicles on the worksite. Follow the instructions of signals and signs. DO NOT operate the vehicle unless: all safety equipment is in proper working condition, all covers and guards are in place, and all safety and instructional decals are in place and readable. (Replace all missing, illegible, or damaged decals.) 2. Clearances Operational Considerations Look out for and avoid other personnel, machinery and vehicles in the area. Travel with the boom fully retracted and lowered as far as possible while still maintaining enough ground clearance for conditions. Always check boom clearances carefully before driving underneath door openings, bridges, etc. Always check for power lines when raising the boom. Beware of overhead wires, contact with electrical power lines can result in electrocution. See Electrocution Hazards on page Underground Hazards Know the location of all underground hazards before operating this vehicle in a new area or worksite. Electrical cables, gas and water pipes, sewer, or other underground objects can cause injury or death. Contact your local underground utility service or diggers hotline to mark all underground hazards Rev 11/99

11 4. Electrocution Hazards Safety Practices NEVER operate this vehicle in an area where overhead power lines, overhead or underground cables, or other power sources may exist without first requesting that the appropriate power or utility company deenergize the lines, or take other suitable precautions. OS Carrying Personnel 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 precautions, see Elevating Personnel on page 76. OS0072 OS Rev 11/99 9

12 Safety Practices 6. Tip Over Hazard OS1633 MAINTAIN proper tire pressures at all times. Underpressurized tire(s) adversely affects vehicle stability. If proper tire pressures are not maintained, this vehicle can tip over. If a vehicle ever becomes unstable and starts to tip over: BRACE YOURSELF and STAY WITH THE VEHICLE, KEEP YOUR SEAT BELT FASTENED, HOLD ON FIRMLY and LEAN AWAY FROM THE POINT OF IMPACT. Indecision and trying to escape from a tipping vehicle can result in death or serious injury. To ensure proper vehicle stability, check all four tire pressures before operating the vehicle. Maintain proper tire pressures. DO NOT exceed the rated lift capacity of the vehicle as structural damage and unstable conditions will result. To ensure that the vehicle is positioned in the most stable condition before operating an attachment: Use the sway control to level the vehicle. The vehicle is level when the frame level indicator gauge reaches (0 ) zero degrees. If the vehicle cannot be leveled using the sway control, reposition the vehicle. Keep the vehicle under control at all times. When negotiating turns, slow down and turn the steering wheel in a smooth sweeping motion. Avoid jerky turns, starts or stops. Reduce vehicle speed on rough ground and slopes Rev 11/99

13 Safety Practices OS0083 Travelling with the boom raised is dangerous and can cause tipover. Keep the boom as low as possible. Travel with extreme caution and at the slowest possible speed. Swaying (frame tilt) left or right with the boom raised above horizontal is dangerous. Always use the sway control to level the vehicle before raising the boom above horizontal, with or without a load. If the vehicle cannot be leveled using sway control, reposition the vehicle. 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 considered 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 slopes with the carriage pointing down the slope. On all slopes, the load must be tilted back and raised only as far as necessary to clear the ground. When operating on a downhill slope, reduce travel speed and downshift to a low gear to permit compression braking by the engine and aid the application of the service brakes Rev 11/99 11

14 Safety Practices 8. Falling Load Hazard DO NOT exceed the total rated load capacity of the specific type fork being used. Each fork is stamped with a maximum load capacity. If the capacity is exceeded, forks may break. See Fork Rating on page 75. DO NOT downshift at a high ground speed. Sudden slowing can cause the load to drop off the forks. 9. Visual Obstruction Dust, smoke, fog, etc. can decrease vision and cause an accident. Always stop or slow the vehicle until the obstruction clears and the worksite is visible again. 10.Ventilation Sparks from the electrical system and the 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 cause suffocation in an enclosed area. Good ventilation is very important when operating this vehicle Rev 11/99

15 Equipment Considerations WARNING Safety Practices DO NOT modify or alter (weld, drill, etc.) any part of this vehicle without consulting Sky Trak. Modifications can weaken the structure creating a hazard that can cause injury or death. DO NOT by-pass or disconnect any electrical or hydraulic circuits. Consult the Sky Trak service department or your Sky Trak distributor if any circuit is malfunctioning. DO check for frayed or cut seat belt webbing, damaged buckles or loose mounting brackets. Replace immediately if required. ALWAYS wear a seat belt when operating the vehicle. DO check tire pressure on all four tires. Add air if required. DO check the condition of all four rims. Check for bent flanges and/or bead mounting areas. DO NOT operate this vehicle unless all protective covers and guards are in place and secure. These devices are installed on the vehicle for your safety and protection. DO check the parking brake operation. Repair immediately if required. DO keep all non-skid surfaces clean and free of debris. Replace if worn, damaged or missing. DO check the condition of important decals. Replace decals if missing, damaged or illegible. Figures 1-4 on the following pages show the proper location of the decals. Figure 1 (page 14) & Figure 2 (page 15) represent vehicles with Work Order No thru Figure 3 (page 16) & Figure 4 (page 17) represent vehicles with Work Order No and After. The Work Order No. is stamped into the serial number plate located on the front of the frame Rev 11/99 13

16 Safety Practices Vehicles Stamped with Work Order No thru DANGER DANGER CONTACTING ELECTRIC POWER LINES can result in electrocution. NEVER operate vehicle within 10 feet (3m) of electric power lines. 3 6 LOW TIRE PRESSURE can result in tipover. MAINTAIN proper tire pressure at all times SAFETY INSTRUCTIONS 1 1. Read operator s manual before operating. 3. Allow no riders Use an approved work 2. Fasten seat belt. platform to lift or lower personnel. OS1511 Item Part Number Quantity Decal Description 1 mold in dash 1 No Riders Warning 2 mold in dash 1 Vehicle Rollaway Warning Electrocution Danger Load Chart Booklet 5 mold in dash 1 Tipover Danger - Operating Tipover Danger - Tire Pressure Safety Instructions NOTE: Many of these hazard related decals are available free of charge by calling OmniQuip Parts Worldwide at (888) Figure Rev 11/99

17 Safety Practices Vehicles Stamped with Work Order No thru OS1256 Item Part Number Quantity Decal Description Moving Parts Warning Explosive Gases Warning Carrying Personnel Warning Boom Extend Stripes Boom Angle Indicator NOTE: All of these hazard related decals are available free of charge by calling OmniQuip Parts Worldwide at (888) Figure Rev 11/99 15

18 Safety Practices Vehicles Stamped with Work Order No and After CONTACTING ELECTRIC POWER LINES can result in electrocution. DANGER NEVER operate vehicle within 10 feet (3m) of electric power lines. VEHICLE TIPOVER can result in death or serious injury. DANGER DO NOT travel with the boom raised. DO NOT raise boom while on a slope unless load is level DANGER LOW TIRE PRESSURE can result in tipover. MAINTAIN proper tire pressure at all times. SAFETY INSTRUCTIONS 1. Read operator s manual 3. Allow no riders. before operating. 4. Use an approved work 2. Fasten seat belt. platform to lift or lower personnel WARNING VEHICLE ROLLAWAY can cause death or serious injury. ALWAYS engage parking brake before dismounting. WARNING Allow no riders. 1 OS1241 Item Part Number Quantity Decal Description 1 mold in dash 1 No Riders Warning 2 mold in dash 1 Vehicle Rollaway Warning Electrocution Danger Load Chart Booklet Tipover Danger - Operating 6 mold in dash 1 Tipover Danger - Tire Pressure 7 mold in dash 1 Safety Instructions NOTE: Many of these hazard related decals are available free of charge by calling OmniQuip Parts Worldwide at (888) Figure Rev 11/99

19 Safety Practices Vehicles Stamped with Work Order No and After OS1255 Item Part Number Quantity Decal Description Moving Parts Warning Explosive Gases Warning Carrying Personnel Warning Boom Extend Stripes Boom Angle Indicator NOTE: All of these hazard related decals are available free of charge by calling OmniQuip Parts Worldwide at (888) Figure Rev 11/99 17

20 Operation Operation Operator Controls Accelerator Pedal (Figure 5) Pressing down the accelerator pedal increases engine and hydraulic speed of the vehicle. The pedal is spring-loaded to return to idle speed. Service Brake Pedal (Figure 5) Pressing down the brake pedal decreases the speed of the vehicle by applying the service brakes located in the axles. In the event of engine power loss the service brake pedal can also be used for emergency braking. Steering Wheel (Figure 5) Turning the steering wheel to the left or right steers the vehicle in the corresponding direction. Any one of three steering modes are selectable. Refer to Steering Select Switch on page 20. Tilt Steering Wheel Lever (Figure 6) To tilt the wheel, hold the steering wheel and pull the lever toward you. Move the steering wheel to a comfotable operating level, then release the lever to lock the wheel in place. Horn Button (Figure 5) Pressing the button sounds the horn. Steering Wheel Horn Button Ignition Switch Service Brake Pedal OS0091 Accelerator Pedal Figure Rev 11/99

21 Operation Steering Wheel - Ref. Tilt Steering Wheel Lever OS1120 Figure 6 Ignition Switch (Figure 7) Using the ignition switch key, the switch may be turned clockwise from the OFF position to the RUN, PREHEAT and START positions. The PREHEAT and START positions are spring-loaded to return to the RUN position and must be manually held in place for starting. OFF position The entire electrical system is shut down. RUN position All controls and indicators are operable. PREHEAT position Optional (Perkins) - Preheats air in the induction manifold for cold weather starting (see Cold Starting on page 45). START position Engages starter motor to crank the engine when the parking brake switch is engaged and the transmission is in NEUTRAL. OFF RUN PREHEAT START OF0390 Figure Rev 11/99 19

22 Operation Travel and Gear Select Lever Steering Selection Indicators Attachment Tilt Mode Switch OS0403 Parking Brake Switch Steering Select Switch (Either of two locations) Steering Select Switch (Figure 8) The switch has three positions: Figure 8 FOUR WHEEL STEERING FRONT WHEEL STEERING CRAB STEERING OS0640 Refer to Steering Modes on page 59 for detailed information Rev 11/99

23 Operation Parking Brake Switch (Figure 8) The parking brake switch has two positions: Engaged... toggle switch downward P OS1323 Disengaged...toggle switch upward P OS0121 The parking brake switch must be ENGAGED to permit engine starting. The parking brake may be used to stop in an EMERGENCY situation however, use caution because the stop will be abrupt and the operator and the load may be jolted forward unexpectedly. Attachment Tilt Mode Switch (Figure 8) OS2120 The attachment tilt mode switch has two positions which allow the operator to chose between Lift/Lower function and the Extend/Retract function accompanying the Attachment Tilt capability. For detailed information, see Multi-Function Joystick Operation starting on page Rev 11/99 21

24 Operation Travel Select Lever (Figure 9) The travel select lever has three positions to select direction of travel: F = FORWARD...all the way UP N = NEUTRAL...CENTER position R = REVERSE...all the way DOWN OS0340 Travel Select Lever OS0130 Figure 9 To change travel selections, grasp the lever and pull it toward the steering wheel, then UP or DOWN to the desired selection. When the travel select lever is shifted to REVERSE, the back-up alarm will automatically sound. NOTE: The travel select lever must be in the (N) NEUTRAL position to permit engine starting Rev 11/99

25 Operation Gear Select Lever (Figure 10) The gear select lever has a twist grip handle with four positions. Vehicles equipped with either Cummins or Perkins turbocharged engine have four (4) forward gears and three (3) reverse. Vehicles equipped with a naturally aspirated Perkins engine have three (3) forward gears and three (3) reverse. Use first gear for highest torque and pulling power. Use higher gears for higher ground speed. Gear Select Lever OS0141 Figure Rev 11/99 23

26 Operation Multi-Function Joystick (Figure 11) Multi-Function Joystick Logic Panel OS0152 Figure 11 The joystick is equipped with four buttons that enable the joystick to operate in four specific modes. The joystick controls boom movement, attachment tilt, sway control and optional auxiliary hydraulics. The logic panel (located in front of the joystick) will illuminate the specific mode that corresponds with the movement of the joystick and the selected buttons. Two functions can be accomplished at the same time by moving the joystick in between quadrants. For example; in Mode 1 moving the joystick forward and to the left will lower and retract the boom simultaneously. The speed of movement depends upon the amount of joystick movement in the corresponding direction. The overall speed of movement depends directly upon engine speed. IMPORTANT! Be aware that joystick modes will change immediately upon depressing or releasing of any button when the joystick is in an off-center position Rev 11/99

27 Operation MODE 1 Boom Control (Default) (No buttons depressed) Boom Lift... logic panel symbol move handle backward OS2050 Boom Lower... Boom Extend... Boom Retract... move handle forward move handle to the right move handle to the left MODE 2A Attachment Tilt Up/Down & Boom Extend/Retract (Right button depressed) Attachment Tilt with Extend & Retract Attachment Tilt Mode Switch In MODE 2A display panel symbol Attachment Tilt Up... logic panel symbol move handle backward OS2060 Attachment Tilt Down... Boom Extend... Boom Retract... Depress Right Button move handle forward move handle to the right move handle to the left 3606 Rev 11/99 25

28 Operation MODE 2B Boom Lift/Lower & Attachment Tilt Up/Down (Right button depressed) Attachment Tilt with Lift & Lower Boom Lift... Attachment Tilt Mode Switch In MODE 2B display panel symbol logic panel symbol move handle backward OS2070 Depress Right Button Boom Lower... Attachment Tilt Down... Attachment Tilt Up... move handle forward move handle to the right move handle to the left Rev 11/99

29 Operation MODE 3 Boom Lift/Lower & Frame Sway Right/Left (Depress left & front button simultaneously, then hold either button) logic panel symbol OS2080 Boom Lift... Boom Lower... Frame Sway Right... Frame Sway Left... move handle backward move handle forward move handle to the right move handle to the left Depress Left & Front Buttons Simultaneously, Then Hold Either Button 3606 Rev 11/99 27

30 Operation MODE 4 Auxiliary Hydraulic Control - Optional (Center button depressed) The auxiliary hydraulic control regulates the functions of an optional attachment. Some of the optional attachments that require auxiliary hydraulics are: Side Tilt Carriage, Swing Carriage. Depress Center Button OS2090 When the joystick is moved to the left, it will provide hydraulic system pressure through the male coupling for the auxiliary attachment. When the joystick is moved to the right, it will provide hydraulic system pressure through the female coupling for the auxiliary attachment. The joystick will provide the following typical functions for each specified attachment listed below if they are connected properly. Operation will be reversed if incorrectly connected. Shutting the vehicle down, releasing the hydraulic pressure and reversing the disconnect couplings on the hoses that are supplied with the attachment will often correct the problem. Contact your local Sky Trak distributor or the Sky Trak service department for more information. Side Tilt Carriage Operation Handle right... tilt right Handle left... tilt left Swing Carriage Operation Handle right... swing right Handle left... swing left Rev 11/99

31 Operation Seat Belt (Figure 12) The seat belt has one retractable strap for easy installation and removal. Insert the seat belt tang into the receptacle to fasten. Press the center button to unfasten the seat belt. Always wear the seat belt when operating the vehicle. An optional 3 inch wide seat belt is available for those locations that require a 3 inch seat belt. Seat Belt OS0200 Figure Rev 11/99 29

32 Operation Operators Seat Adjustments (Figure 13) The operator s seat can be adjusted three ways: A. Fore and Aft Adjustment - Pull the handle outward to adjust the seats forward and rearward position. Release the handle to lock the seat in the desired position. B. Suspension Adjustment - Turn the knob or handle on the front of the seat to adjust the suspension to correspond with the operator s weight. Turn clockwise to increase stiffness. Turn counter-clockwise to reduce the stiffness. C. Backrest Angle Adjustment - The angle of the seats backrest can be adjusted to suit the operator. Move the lever or turn the knob located on the left side of the seats backrest to adjust the angle. C C B A A OS0200 B OS2110 STANDARD SEAT DELUXE SEAT Figure Rev 11/99

33 Operation Operators Display Panel The display panel provides the operator with important information. It is user friendly and only provides the operator with the information needed at any given time. POWER-UP Lights (Figure 14) At POWER-UP the display panel will illuminate all its lights for several seconds as a test function. During this time an audible alarm will sound. The FASTEN SEAT BELT and READ OPERATOR MANUAL symbols will remain illuminated for five to seven seconds. This is an important reminder to the operator to fasten the seat belt and to review the operators manual if there are any questions about safe operation. After the five to seven second time period the audible alarm will cease and the FASTEN SEAT BELT and READ OPERATOR MANUAL symbols will go out. If at any time the operator gets up off the seat, these lights will illuminate again and shut off shortly after the operator sits back down. Do not forget to refasten your seat belt before operation. Always wear the seat belt when operating the vehicle D F N R P EARLY PRODUCTION VEHICLES CURRENT PRODUCTION VEHICLES OS0222 Figure Rev 11/99 31

34 Operation Normal Operating Lights (Figure 15) After the engine has started, the display panel provides the operator with information about: A. Fuel Level Indicators Make sure the vehicle is level to ensure an accurate fuel level reading. Each bar represents 1/4 of the tank. The fuel level indicator symbol will illuminate a low level GREEN light for night visibility. When 1/8 tank is reached the last bar will turn OFF and the fuel level indicator symbol will change from a GREEN indicator to an intense ORANGE indicator light. Refuel at this point. B. Travel & Gear Select Indicators The light that illuminates indicates which direction the vehicle is presently travelling and the gear presently engaged. C. Steering Mode Indicators The light that illuminates will indicate which steering mode is presently engaged. D. Attachment Tilt Mode Indicator One of these two lights will be illuminated to indicate which attachment tilt mode is presently engaged. Fuel Level Indicator Bars B Gear Select Indicators A C F N R Fuel Indicator Symbol Travel Select Indicators D OS0211 Figure Rev 11/99

35 Operation Function Indicator Lights (Figure 16) There are three hidden function indicator lights in the display panel that become illuminated only when a specific function has been activated. They are: A. Engine Preheat Indicator (Optional) This light will begin to flash when the operator holds the ignition key in the PREHEAT position. After 30 seconds the light will glow steadily, indicating the engine is warm enough to start. B. Parking Brake Indicator This light becomes illuminated any time the parking brake switch is applied and the ignition switch is ON. C. Stabil-TRAK Indicator This light becomes illuminated when the system has been activated. A C B F N R P A EARLY PRODUCTION VEHICLES B C D F N R P CURRENT PRODUCTION VEHICLES OS0492 Figure Rev 11/99 33

36 Operation Warning Indicator Lights (Figure 17) There are eight additional hidden indicator lights in the display panel that become illuminated during critical circumstances. All eight warning indicator lights demand immediate attention and vehicle servicing. In many cases the vehicle should be shut down AS SOON AS PRACTICAL to prevent serious mechanical failure. B C A D D F N R E F G H OS0531 Figure 17 The eight warning indicator lights are: A. Engine Maintenance/Vehicle Lubrication Indicator - This light becomes illuminated every 250 hours of operation. Call for service. This indicator reminds the operator that important maintenance operations are required at this time. After servicing, the indicator can be reset by depressing and holding the reset button (Figure 18) then turning the ignition switch to the ON position. The indicator light will illuminate during power-up and will go out when it is reset. The reset button can then be released. B. Engine Coolant Temperature Warning Indicator - This light becomes illuminated when the engine coolant temperature is too high; above 210 F (85 C). An audible alarm will also sound. SHUT THE VEHICLE DOWN AS SOON AS PRACTICAL. C. Transmission Temperature Warning Indicator - This light becomes illuminated when the transmission oil temperature is too high; above 250 F (107 C). An audible alarm Rev 11/99

37 Operation will also sound. Stop and idle the vehicle, allowing time for cooling. If the light does not go out after five minutes, shut the vehicle down. Reset Button for Engine Maintenance/ Vehicle Lubrication Indicator OS0251 Figure 18 D. Hydraulic Oil Temperature Warning Indicator - This light becomes illuminated when the hydraulic oil temperature is too high; above 195 F (76 C). Stop and idle the engine, allow time for cooling. If the light does not go out after five minutes, shut the vehicle down. E. Engine Oil Pressure Warning Indicator - This indicator light will come ON and an audible alarm will sound after 15 seconds if the engine is not started. This is normal. Turn the ignition switch OFF to reset the indicator. If the light comes ON while the engine is running, this indicates that the engine oil pressure is too low. SHUT THE VEHICLE DOWN AS SOON AS PRACTICAL. F. Alternator Charging Warning Indicator - This light becomes illuminated when the charging system is not working properly. Service the engine alternator. G. Engine Air Filter Restriction Warning Indicator - This light becomes illuminated when a restricted engine air filter is detected. If the light begins to flicker ON and OFF at high idle, service the air filter(s). H. Hydraulic Oil Filter Restriction Warning Indicator - This light becomes illuminated when a restricted hydraulic oil filter is detected. If the light begins to flicker ON and OFF at high idle, service the hydraulic oil filter Rev 11/99 35

38 Operation Instruments and Indicators Hourmeter (Figure 19) OS0260 The hourmeter records engine operating hours and has a total readout of 99,999.9 hours. It is located on the left side of the operators console and is best viewed from outside the vehicle. Hourmeter OS0750 Figure 19 Frame Level Indicator (Figure 20) The frame level indicator is mounted on the top inside of the cab. This is a bubble type indicator which allows the operator to tell if the vehicle has been positioned in a level condition. Always sway (frame tilt) the vehicle either right or left until the indicator reads zero degrees (0 ). If zero cannot be achieved, then reposition the vehicle until it is level before placing the load. Frame Level Indicator OS0232 Figure Rev 11/99

39 Operation Boom Angle Indicator (Figure 21) The boom angle indicator is a plumb arrow with angular graduations from -10 to It is located on the left side of the boom and is visible from the operators position. Use this indicator to determine the boom angle when reading the capacity chart (see Using the Capacity Chart ). Boom Angle Indicator OS0240 Figure 21 Rear View Mirrors (Figure 22) Two rear view mirrors are provided to aid the operators rear visibility. The mirrors are adjustable and need to be adjusted to obtain the best rear view possible for the operator. An optional third mirror is available inside the cab. Two Standard Rear View Mirrors Optional Mirror Cab (Ref.) OS1470 Engine Cover (Ref.) OS1050 Figure Rev 11/99 37

40 Operation Optional Controls Manually Operated Pressure Release Valve (Figure 23) OS2140 The pressure release valve is located in the rear of the vehicle and is used to release pressure before connecting or disconnecting the optional Auxiliary Hydraulic Couplings. For a step by step procedure on how to manually operate the pressure release valve, see page 66 later in this section. Manually Operated Release Valve OS0360 Figure 23 Lights (Figure 24) OS1900 The lights are activated with a toggle switch located in a bank of switches on the left side of the dash. There are three positions - OFF, Front Lights and All Lights (Front Lights & Worklight). The lights work with or without the ignition switch in the RUN position. Light Switch OS1840 Figure Rev 11/99

41 Operation Directional Signals (Figure 25) OS1910 The directional signals are activated from the lever on the right side of the steering wheel. To activate the left turn signal, raise the lever. To activate the right turn signal, lower the lever. To deactivate either directional signal, the lever must be manually returned to the center position, the lever will not cancel automatically after a turn. Emergency Flashers (Figure 25) OS1920 To activate the emergency flashers, rotate the twist grip clockwise. To deactivate the emergency flashers, rotate the twist grip counter-clockwise. Left Turn Signal Emergency Flashers Right Turn Signal OS1821 Figure 25 Door Latches (Not Pictured) There are two door latches. The outside latch is a key lockable pull to release type. The inside latch is also a pull to release latch Rev 11/99 39

42 Operation Power Window (Figure 26) OS1850 The power window control is a momentary toggle switch that will raise or lower the cab door window when the ignition is in the RUN position. To lower the window, toggle the switch downward to the desired position then release the switch. NOTE: The window will not lower entirely into the door; it will stop approximately half way down and not go any further. To raise the window, toggle the switch upward to the desired position and then release the switch. Cab Door Power Window Switch Door Latch (Ref.) OS1800 Rear Window Latches (Figure 27) Figure 26 The rear window can be partially opened and secured in place with the rear window latches. To open the window, grab both latch handles simultaneously and pull up and then push the window outward. To close and secure the window, pull both latch handles up and then inward. NOTE: In an emergency situation, the operator can exit through the rear window opening by removing the latch pins on both window latches. The window is then free to swing open Rev 11/99

43 Operation Latch Pin (Ref.) Rear Window Latch Handle OS1830 Front Windshield Wiper Front Windshield Washer (Figure 28) Figure 27 OS1930 OS1940 The front wiper switch and the front washer switch are separate switches located in the right-hand bank of switches on the dash. Skylight Wiper/Washer (Figure 28) OS2100 The skylight (roof) wiper/washer switch is located in the right-hand bank of switches on the dash. Front Washer Switch Front Wiper Switch Skylight Wiper/Washer Switch OS1840 Figure Rev 11/99 41

44 Operation Cab Heater/ Cab Air Conditioning Controls OS1950 OS1960 (Figure 29) The cab heater and air conditioning controls are located directly below the vehicles Capacity Chart Booklet. From left to right the control panel consists of: a stepped fan control knob, an A/C on-off rocker switch (A/C units only), and a temperature control knob. Fan Control A/C ON-OFF Rocker Switch (A/C Units Only) Temperature Control OS2031 Figure 29 Control of air flow is made by opening, closing or redirecting the air vent louvers in five seperate locations inside the cab. For instance, if the front glass needs rapid defrosting, redirect the air flow at the front two vents (directing the vent louvers toward the glass) and close the remaining three vents. This will increase the volume of air flow to the front glass and speed defrosting. To heat the cab: if so equipped, turn A/C rocker switch to OFF position, turn temperature control knob to far right position (red = hot), direct desired air flow by adjusting vent louvers, turn fan control to 3 to assure rapid warm-up Rev 11/99

45 To defrost the cab: Operation turn temperature control knob to far right position (RED=HOT), direct desired air flow by adjusting vent louvers, turn fan control to 3 to assure rapid defrost. To cool the cab: turn A/C rocker switch to ON position, turn temperature control knob to far left position (BLUE=COOL), direct desired air flow by adjusting vent louvers, turn fan control to 3 to assure rapid cool-down. Pre-Operation Inspection 1. Check safety belt for damage. Check for frayed or cut seat belt webbing, damaged buckles or loose mounting brackets. Make any necessary repairs before operating the vehicle. 2. Check all four tires and rims for damage. Check for proper tire pressure, add air if required. Observe the condition of each tire looking specifically for punctures, cracks, cuts, gouges, bulges or any other damage. Check the condition of each rim for bent flanges or any other damage. Make any necessary repairs before operating the vehicle. 3. Check and add engine oil if required. This procedure is explained in greater detail on page Check and add transmission oil if required. This procedure is explained in greater detail on page Check the cooling system overflow bottle for coolant. Add coolant if required. This procedure is explained in greater detail on page 111. Remove any debris blocking the radiator cooling fins. 6. Check the hydraulic oil level sight glass and add hydraulic oil if required. This procedure is explained in greater detail on page Walk around the vehicle and check for oil leakage as well as damaged or missing parts. Make any necessary repairs before operating the vehicle Rev 11/99 43

46 Operation Normal Starting 1. Enter the cab and adjust the seat for comfortable operation. 2. Adjust the mirrors to obtain the best rear view from the operators position. WARNING DO NOT start the engine unless you are in the seat with the seat belt fastened around you. Serious injury or death could result if the belt is not securely fastened. 3. Fasten the seat belt. 4. Make sure the parking brake switch is ENGAGED. 5. Place the travel select lever in (N) NEUTRAL. 6. Turn the ignition switch to the START position (fully clockwise) to crank the engine. Release the key when the engine starts. If the engine fails to start on the first try, wait until the engine and starter come to a complete stop before cranking the engine again. IMPORTANT! DO NOT crank the starting motor continuously for more than 15 seconds. This will avoid starter motor overheating. 7. After the engine starts, run engine at partial throttle for 30 to 60 seconds before operating the vehicle. Return to idle before engaging the travel or range select levers. 8. Disengage the parking brake switch before you start operating Rev 11/99

47 Operation Cold Starting (Perkins Engines Only) Use the PREHEAT cold starting aid when the temperature is below 32 F (0 C) with 10W30 oil in the engine crankcase. Using the block heater is recommended when temperatures fall below 10 F (-12 C). (Temperature ranges will vary when using different oil weight. Consult the engine manufacturer s manual for other variables.) At temperatures below 10 F (-12 C), operate the engine at moderate speeds for 5 minutes before full loads are applied. WARNING This diesel engine uses a PREHEAT system for cold weather starting. DO NOT use ether or any high energy fuels to assist starting. An explosion may cause serious injury or engine damage. 1. Enter the cab and adjust the seat for comfortable operation. Adjust the mirrors if necessary. WARNING DO NOT start the engine unless you are in the seat with the seat belt fastened around you. Serious injury or death could result if the belt is not securely fastened. 2. Fasten the seat belt. 3. Make sure the parking brake is engaged. 4. Make sure the travel select lever is in the (N) NEUTRAL position Rev 11/99 45

48 Operation 5. Turn and hold the ignition switch to the PREHEAT position until the preheat indicator light on the display panel stops flashing and glows steadily. Release the switch immediately after the light goes out. For location of the preheat indicator light on the display panel see page 33. OFF RUN PREHEAT START OF0390 Figure Depress the accelerator pedal completely. 7. Turn the ignition switch to the START position to engage the starter motor. As the engine starts, release the ignition key to the RUN position. Release the accelerator pedal enough to provide a smooth idle speed. 8. If the engine does not start in 15 seconds, return the ignition key to the PREHEAT position for an additional 10 seconds and then engage the starter motor again Rev 11/99

49 Operation Cold Starting (Cummins Engines Only) The Cummins engine is equipped with a block heater. Block heaters are recommended when temperatures drop below 10 F (-12 C). (Temperature ranges will vary when using different oil weights. Consult the engine manufacturer s manual for other variables.) At temperatures below 10 F (-12 C), operate the engine at moderate speeds for 5 minutes before full loads are applied. 1. Enter the cab and adjust the operator s seat. WARNING DO NOT start the engine unless you are in the seat with the seat belt fastened around you. Serious injury or death could result if the belt is not securely fastened. 2. Fasten the seat belt. Adjust the mirrors if necessary. 3. Make sure the parking brake switch is ENGAGED. 4. Make sure the travel select lever is in the (N) NEUTRAL position. 5. Depress the accelerator pedal half way to the floor. 6. If using starting fluid with mechanical or electrical metering equipment: turn the ignition switch to the START position to engage the starter motor and inject metered amounts of starting fluid. as the engine starts, stop injection of starting fluid and release the ignition key to the RUN position. Release the accelerator pedal enough to provide a smooth idle speed Rev 11/99 47

50 Operation 7. If using starting fluid without metering equipment: WARNING NEVER use starting fluid near an open flame. NEVER use starting fluid in a vehicle equipped with an electrical preheat option or flame air heating equipment. DO NOT breathe starting fluid fumes. Serious injury or death could result from toxic fumes. DO NOT use excessive amounts of starting fluid when cold starting an engine. Serious injury or death could result from backfire of flame which could ignite the starting fluid canister and cause an explosion. IMPORTANT! It is recommended that a second person be present when attempting to cold start the engine without metered starting fluid equipment. One person will sit in the operators seat and operate the ignition switch and another helper is needed to spray the starting fluid. IMPORTANT! It is important to know that timing is crutial in cold starting an engine. DO NOT spray ether into the air cleaner intake before the procedure instructs you to. CAUTION DO NOT use excessive amounts of starting fluid. Because it is difficult to describe how much starting fluid should be used, it is important to avoid soaking the air cleaner element. An engine backfire could destroy the internal air cleaner elements and other engine damage may occur. It is much better to spray the fluid intermittently than continually spraying.. turn the ignition switch to the START position to engage the starter motor (Figure 31). After the engine has started to crank, not before, the other person can begin spraying starting fluid into the air cleaner intake (Figure32) Rev 11/99

51 Operation as the engine starts, stop spraying the starting fluid and release the ignition switch to the RUN position. Release the accelerator pedal enough to provide a smooth idle speed. 8. The engine oil pressure warning indicator light should go off within 5 seconds after starting. If the light remains on, turn the ignition switch OFF immediately and check the oil level or change to a lighter weight oil. Consult the engine manufacturer s manual for alternative oils for cold weather operation. OFF RUN PREHEAT START OF0390 Figure 31 Engine Cover Air Cleaner Assembly Air Cleaner Intake OS1500 Figure Rev 11/99 49

52 Operation Jump Starting WARNING NEVER jump start the vehicle directly to the starter or starter solenoid. Serious injury or death could result from the vehicle lurching forward or backward and running over the person attempting to jump start the vehicle directly to the starter. WARNING To avoid personal injury when jump starting with another vehicle, be certain that the two 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. 1. The booster battery must be a 12 volt type. The vehicle used for jump starting must have a negative ground electrical system. To jump start the vehicle, proceed as follows: 2. Connect the positive (+) jumper cable to the positive (+) post of the discharged battery. 3. Connect the other end of the positive (+) jumper cable to the positive (+) post of the booster battery. 4. Connect one end of the negative (-) jumper cable to the negative (-) post of the booster battery. 5. Make the final cable connection to the engine block ground or the furthest point from the battery. 6. Follow the steps in Normal Starting on page Rev 11/99