SkyTrak 8042 Operation Manual Instruction Manuals and User Guides
We have 3 Instruction Manuals and User Guides for 8042 Operation Manual SkyTrak
Manuals 
| Recognized languages: | English |
|---|---|
| Pages: | 170 |
| Size: | 5.11 MB |
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Document Outline
- 31200352_H_6036 6042 8042 10042 10054_SkyTrak_Operation-Safety
- Revision Log
- Read This First
- Table of Contents
- Section 1 - General Safety Practices
- Section 2 - Pre-Operation and Inspection
- Section 3 - Controls and Indicators
- Section 4 - Operation
- Section 5 - Attachments
- 5.1 Approved Attachments
- 5.2 Unapproved Attachments
- 5.3 JLG Supplied Attachments
- 5.4 Telehandler/Attachment/Fork Capacity
- 5.5 Use of the Capacity Chart
- 5.6 Attachment Installation
- 5.7 Adjusting/Moving Forks
- 5.8 Attachment Operation
- Carriage w/Forks
- Side Tilt Carriage
- Swing Carriage
- Dual Fork Positioning Carriage
- Mast Carriage (S/N 0160037788 & After)
- Fork Mounted Hook
- Fork Extension
- Truss Boom
- Bucket
- Grapple Bucket (S/N 0160037788 & After)
- Concrete Bucket (Before S/N 0160037788)
- Auger (Before S/N 0160037788)
- Sweeper (Before S/N 0160037788)
- Personnel Work Platform
- Section 6 - Emergency Procedures
- Section 7 - Lubrication and Maintenance
- Section 8 - Additional Checks
- Section 9 - Specifications
- Index
- Inspection, Maintenance and Repair Log
| Recognized languages: | English |
|---|---|
| Pages: | 190 |
| Size: | 4.67 MB |
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Document Outline
- 8990500_C_8042_SkyTrak_Operator
- TOC
- Introduction
- Safety Practices
- Disclaimer
- Hazard Classification System
- Accident Prevention Tags
- New or Additional Operators
- Instructional Symbols
- Hazard Symbols
- Avoidance Symbols
- Avoidance Symbols (cont’d)
- Personal Considerations
- 2. Clothing and Safety Gear
- 3. Dismounting
- 4. Chemical Hazards
- 5. Moving Parts Hazard
- 6. Lowering Boom or Falling Load Hazard
- 2. Clearances
- 3. Visual Obstruction
- 4. Underground Hazards
- 5. Electrocution Hazards
- 6. Elevating Personnel
- 7. Tip Over Hazard
- 8. Emergency Exit Rear Window
- 9. Tire Pressure
- 10. Do Not Jump
- 11. Slopes
- 12. Falling Load Hazard
- 13. Ventilation
- Operation
- Operator Controls
- Accelerator Pedal
- Service Brake Pedal
- Steering Wheel
- Horn Button
- Ignition Switch
- Steering Select Switch
- Park Brake Switch
- Neutral Lock Lever
- Travel Select Lever
- Gear Select Lever
- Recommended Gear/Speed for Various Load/Travel Conditions
- Load Size
- Surface
- Gear
- Speed
- No Load
- Smooth
- 4th*
- 0 to 20 mph (0 to 32 km/h)
- Improved
- 3rd
- 0 to 14 mph (0 to 23 km/h)
- Rough
- 2nd
- 0 to 6 mph (0 to 9,7 km/h)
- Load
- Smooth
- 3rd
- 0 to 14 mph (0 to 23 km/h)
- up to 4,500 lbs
- Improved
- 2nd
- 0 to 6 mph (0 to 9,7 km/h)
- (up to 2.041 kg)
- Rough
- 2nd
- 0 to 6 mph (0 to 9,7 km/h)
- Load
- Smooth
- 3rd
- 0 to 14 mph (0 to 23 km/h)
- 4,500 to 8,000 lbs
- Improved
- 2nd
- 0 to 6 mph (0 to 9,7 km/h)
- (2.041 to 3.629 kg)
- Rough
- 1st
- 0 to 3.5 mph (0 to 5,6 km/h)
- Boom Control Lever
- Attachment Tilt and Frame Sway Control Lever
- Seat Belt
- 1. Grasp both free ends of the belt and make certain that the belt webbing is not twisted or enta...
- 2. With your back straight in the seat, couple the retractable end or the male end of the belt in...
- 3. With the belt buckle as low on your body as possible, pull the retractable end of the belt or ...
- 4. To release the belt latch, depress the red button (1) or lift the black cover (2) of the buckl...
- Operator’s Seat Adjustment
- B. Suspension Adjustment
- C. Backrest Angle Adjustment
- B. Park Brake Light
- C. High Beam Light
- D. Turn Signal Light
- B. Transmission Temperature Warning Indicator Light
- C. Hydraulic Oil Temperature Warning Indicator Light
- D. Engine Oil Pressure Warning Indicator Light
- E. Alternator Charging Warning Indicator Light
- B. Engine Function Indicator Lights
- Frame Level Indicator
- Boom Angle Indicator
- Rear View Mirrors
- Optional Controls
- Pre-Operation Inspection
- 1. Check safety belt for damage. Check for frayed or cut seat belt webbing, damaged buckles or lo...
- 2. Check all four tires and rims for damage. Check for proper tire pressure, add air if required....
- 3. Check and add engine oil if required. This procedure is explained in greater detail on page119.
- 4. Check and add transmission oil if required. This procedure is explained in greater detail on p...
- 5. Check the cooling system overflow bottle for coolant. Add coolant if required. This procedure ...
- 6. Check the hydraulic oil level sight glass and add hydraulic oil if required. This procedure is...
- 7. Walk around the vehicle and check for oil leakage as well as damaged or missing parts. Make an...
- Normal Starting
- 1. Enter the cab using the hand holds and adjust the seat for comfortable operation.
- 2. Adjust the mirrors to obtain the best rear view from the operator’s position.
- 3. Fasten the seat belt.
- 4. Make sure the parking brake switch is ENGAGED.
- 5. Place the travel select lever in (N) NEUTRAL and move the neutral lock lever to NEUTRAL LOCK p...
- 6. Turn the ignition switch to the START position (fully clockwise) to crank the engine. Release ...
- 7. After the engine starts, run engine at partial throttle for 30 to 60 seconds before operating ...
- 8. Move the Neutral Lock Lever to the (D) DRIVE position before you start operating.
- 9. Disengage the parking brake switch before you start operating.
- Cold Starting
- 1. Enter the cab using the hand holds and adjust the seat for comfortable operation.
- 2. Adjust the mirrors to obtain the best rear view from the operator’s position.
- 3. Fasten the seat belt.
- 4. Make sure the parking brake switch is ENGAGED.
- 5. Place the travel select lever in (N) NEUTRAL and move the neutral lock lever to NEUTRAL LOCK p...
- 6. Turn the ignition switch to the START position to crank the starter.
- 7. As the engine starts, release the ignition switch to the RUN position. Depress the accelerator...
- 8. The engine oil pressure warning indicator light should go OFF within five seconds after starti...
- Jump Starting
- 1. Connect the positive (+) jumper cable to the positive (+) post of the discharged battery.
- 2. Connect the other end of the positive (+) jumper cable to the positive (+) post of the booster...
- 3. Connect one end of the negative (-) jumper cable to the negative (-) post of the booster battery.
- 4. Make the final cable connection to the furthest point from the batteries.
- 5. Follow the steps in “Normal Starting” on page55.
- 6. Remove the jumper cables in the reverse order of their connection (i.e. negative cable ground ...
- Refueling
- Stabil-TRAK System
- Operating
- Starting Travel
- 1. Enter the operator cab, fasten the seat belt, start the engine, apply the service brake pedal ...
- 2. Rotate the twist grip of the range select lever (4) to 1st gear.
- 3. Move the travel select lever (5) to (F) FORWARD to travel in a forward direction or to (R) REV...
- 4. Slowly remove your foot from the service brake pedal and press the accelerator pedal to start ...
- Changing Travel Direction
- Shifting Gears
- Recommended Gear/Speed for Various Load/Travel Conditions
- Load Size
- Surface
- Gear
- Speed
- No Load
- Smooth
- 4th*
- 0 to 20 mph (0 to 32 km/h)
- Improved
- 3rd
- 0 to 14 mph (0 to 23 km/h)
- Rough
- 2nd
- 0 to 6 mph (0 to 9,7 km/h)
- Load
- Smooth
- 3rd
- 0 to 14 mph (0 to 23 km/h)
- up to 4,500 lbs
- Improved
- 2nd
- 0 to 6 mph (0 to 9,7 km/h)
- (up to 2.041 kg)
- Rough
- 2nd
- 0 to 6 mph (0 to 9,7 km/h)
- Load
- Smooth
- 3rd
- 0 to 14 mph (0 to 23 km/h)
- 4,500 to 8,000 lbs
- Improved
- 2nd
- 0 to 6 mph (0 to 9,7 km/h)
- (2.041 to 3.629 kg)
- Rough
- 1st
- 0 to 3.5 mph (0 to 5,6 km/h)
- NOTE: Shifting to the next higher gear may be done while the vehicle is in motion.
- Stopping Travel
- Steering Modes
- Four Wheel Steer Indexing
- 1. Four Wheel Steering
- 2. Front Wheel Steering
- 3. Crab Steering
- 4. Maximum Fork Sweep
- Leveling Frame
- Quick Attach
- Attachment Removal
- 1. Place the travel select lever in (N) NEUTRAL, come to a complete stop, move the neutral lock l...
- 2. Extend the boom approximately 10 feet (3 meters) and tilt the carriage backward.
- 3. Exit the vehicle using the hand holds.
- NOTE: If you are removing a standard carriage with forks, spread the forks apart on the carriage ...
- 4. Raise the quick attach pin lock lever (1) and pull out the pin (2) at the bottom of the quick ...
- 5. Return to the operators compartment, fasten the seat belt and lower the attachment to the grou...
- 6. Lower and then retract the boom until the attachment pivot pins have disconnected from the att...
- Attachment Reconnect
- 1. Position the vehicle directly behind the attachment to be mounted.
- 2. Tilt the quick attach backward.
- 3. Extend the boom approximately 10 feet (3 meters) and drive the vehicle forward until the attac...
- 4. Raise the boom until the attachment pivot pins have seated fully in the hooks of the attachment.
- 5. Tilt the attachment up slightly. The quick attach link should be tight against the rear of the...
- 6. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK posi...
- 7. Lift the quick attach lever (1). Insert the quick attach pin (2) completely through the attach...
- 8. Return to the cab, fasten the seat belt and resume operation.
- Starting Travel
- Using The Capacity Chart
- 1. Weight of the load being lifted.
- 2. Height of the structure where the load is to be placed.
- 3. Distance where the load will ultimately be placed in front of the front tires.
- Reading The Capacity Chart
- Standard Carriage Capacity Chart
- Side Tilt Carriage Capacity Chart
- Swing Carriage Capacity Chart
- 12 Foot Truss Boom Capacity Chart
- 3 Foot Truss Boom w/Winch Capacity Chart
- Fork Ratings
- How To Pick, Carry & Place A Load
- Elevating Personnel
- b. Width of the platform shall not be wider than the width of the vehicle, measured across the lo...
- c. Minimum space requirements for each person on the platform shall not be less than 18" (450 mm)...
- 3. The platform shall have a 4" (100 mm) minimum high toe plate around the perimeter of the platf...
- 4. Protection must be provided for the personnel on the work platform from any pinch points or mo...
- 5. Information prominently indicated on the work platform shall include:
- a. Maximum work load including personnel and equipment.
- b. Weight of the empty platform.
- b. Prevent the platform from inadvertent pivoting.
- 7. The platform must have a restraining means such as a guardrail or a means of securing personne...
- 8. The guardrail or similar structure shall have a nominal height to the platform floor of 42" (1...
- 9. The guardrail shall be capable of withstanding a concentrated horizontal force of 200 lb (890 ...
- 10. A body belt and lanyard is to have an attaching point for freedom of movement, and its length...
- 11. Lanyards, when provided, shall be arranged so as not to cause a tripping hazard.
- 12. Body belts, when provided, should have a width of at least 1.75 in. (44mm).
- 13. Structural safety factor - all load supporting structural elements of the work platform shall...
- Capacity Limitations
- Preparation and Set-up
- 1. DO NOT alter or modify the work platform in any manner.
- 2. Make sure that the work platform is securely attached to the quick attach or forks. Follow the...
- 3. Make sure the platform, carriage and forks are secured to prevent them from pivoting from side...
- 4. On side tilt or swing carriages, the carriage must be centered and/ or leveled horizontally an...
- 5. Ensure the vehicle has a firm footing and is level.
- 6. Be sure the vehicle is in a level position (side to side) before any operation is begun. Use t...
- 7. Place the travel select lever in the (N) NEUTRAL position and move the neutral lock lever to t...
- 8. Engage the parking brake switch. Blocking the wheels is also recommended.
- 9. Level the platform in both the side-to-side and front-to-back directions before use.
- 10. Before lifting or lowering personnel, be sure the vehicle lifting mechanism operates smoothly...
- 11. Be sure any lift limiting devices and latches are functioning properly.
- 12. Any body belt, lanyard or deceleration devices which have sustained any deformation or damage...
- 13. Before elevating personnel, the area around and under the work platform should be marked to w...
- 14. Protection must be provided for the personnel on the work platform from any pinch points or m...
- 15. Provide any overhead protection device as required by worksite conditions or if requested by ...
- Elevating Personnel
- 1. Make sure there are no overhead obstructions or electrical wires above the platform before lif...
- 2. A trained operator must operate the controls from the operators compartment and must remain wi...
- 3. Personnel aboard the work platform must maintain a firm footing at all times.
- 4. Be certain the personnel and related equipment on the platform do not exceed the available spa...
- 5. The platform shall be lowered to the ground level for personnel to enter or exit the platform ...
- 6. Always position the platform in the travel position (approximately one foot above ground level...
- Using Other Attachments
- Shut-Off
- 1. Bring the vehicle to a complete stop using the service brakes.
- 2. Park the vehicle on level ground.
- 3. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK posi...
- 4. Lower the boom and ground the carriage.
- 5. Turn the ignition key to the OFF position and remove the key.
- Operator Controls
- Emergency Operations
- Towing A Disabled Vehicle
- 1. Remove the load from the vehicle.
- 2. Block all four wheels to help prevent the vehicle from moving after the parking brake is disab...
- 3. Remove the six hex nuts (1) securing the transmission covers (2) to the frame. Remove the covers.
- 4. Position the towing vehicle in place. Attach any chains needed to secure the disabled vehicle.
- 5. Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port (1) on th...
- 2
- 6. Turn the key switch to the ON position (with the engine not running), release the park brake (...
- 7. Pressurize the park brake with the pressurizing unit. Close the pump needle valve on the press...
- 8. Clear the area of all unnecessary personnel.
- 9. Carefully remove the wheel blocks from each of the four tires. Tow the vehicle to a secure loc...
- Emergency Boom Lowering
- Part I
- Loss of Engine Power or Hydraulic Pump Failure
- 1. Clear the area around the vehicle of all personnel.
- 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK posi...
- 3. Block all four wheels.
- 4. Section off a large area under the boom with string or tape to restrict any personnel from ent...
- 5. Temporarily block up or support the outer boom so it cannot be lowered.
- 6. If the load is in a position where it can be removed safely, completely remove the load from t...
- 7. Place an accident prevention tag on both the ignition switch and steering wheel. Refer to “Acc...
- Part ll - Hydraulic Line Failure
- 3
- STEP 1
- 1. Clear the area of any unnecessary personnel.
- 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK posi...
- 3. Block all four wheels.
- 4. If the load is in a position where it can be removed safely, completely remove the load from t...
- 5. Temporarily block up or support the outer boom.
- 6. Replace the failed hydraulic line with a new part. The hydraulic lines are:
- 7. Check the hydraulic oil level, add oil if needed.
- 8. Remove the blocking or support from the outer boom.
- 9. Return to the cab, fasten your seat belt and start the engine.
- 10. Tilt the carriage and/or attachment upward if necessary for clearance before retracting the b...
- 11. Slowly retract the boom.
- 12. Slowly lower the boom and ground the carriage and/or attachment.
- 13. Shut off the engine.
- 14. Completely remove the load from the carriage and/or attachment if you haven’t already done so.
- 15. Return to the cab, fasten your seat belt and start the engine.
- 16. Cycle the lift and extend cylinders several times to bleed air from the system. Check for leaks.
- 17. Recheck the hydraulic oil level. Add oil if necessary.
- STEP 1
- 3
- STEP 2
- 1. Clear the area of any unnecessary personnel.
- 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK posi...
- 3. Block all four wheels.
- 4. Place a container under the failed hose to catch any hydraulic oil that may escape during this...
- 5. Return to the cab, fasten your seat belt and start the engine.
- 6. Slowly retract the boom.
- 7. Slowly lower the boom and ground the carriage and/or attachment.
- 8. Shut off the engine.
- 9. Completely remove the load from the carriage and/or attachment.
- 10. Place an accident prevention tag on both the ignition switch and steering wheel. Refer to “Ac...
- 11. Have the vehicle serviced immediately. Replace any failed hydraulic lines with new parts. The...
- 12. Return to the cab, fasten your seat belt and start the engine.
- 13. Cycle the lift cylinder several times to bleed air from the system. Check for leaks.
- 14. Recheck the hydraulic oil level. Add oil if necessary.
- 15. Transfer any waste oil to a container with a cover and label as used oil. Dispose of properly.
- STEP 2
- 3
- STEP 3
- 1. Clear the area of any unnecessary personnel.
- 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK posi...
- 3. Block all four wheels.
- 4. Temporarily block up or support the outer boom.
- 5. If the load is in a position where it can be removed safely, completely remove the load from t...
- 6. Place a 10 gallon (40 liter) container under the vehicle to catch any hydraulic oil that will ...
- NOTE: If a replacement hose is not available, the adjacent boom lift line (1) can be used to repl...
- 7. Remove the individual failed boom lower line from the circuit.
- 8. Remove and temporarily reposition the adjacent boom lift line (1) in place of the failed boom ...
- 9. Check the hydraulic oil level and add oil if needed.
- 10. Remove the blocking or support from the outer boom.
- 11. Return to the cab, fasten your seat belt and start the engine.
- 12. Tilt the carriage and/or attachment upward if necessary for clearance before retracting the b...
- 13. SLOWLY RETRACT the boom.
- 14. SLOWLY LOWER the boom and ground the carriage.
- 15. Completely remove the load from the carriage and/or attachment if you haven’t already done so.
- 16. Have the vehicle serviced immediately.
- 17. Replace any faulty hydraulic lines.
- 18. Return to the cab, fasten your seat belt and start the engine.
- 19. Cycle the lift cylinder several times to bleed air from the system. Check for leaks.
- 20. Transfer the waste oil to a container with a cover and label as used oil. Dispose of properly.
- 21. Recheck the hydraulic oil level. Add oil if necessary.
- STEP 4
- 1. Clear the area of any unnecessary personnel.
- 2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK posi...
- 3. Block all four wheels.
- 4. If the load is in a position where it can be removed safely, completely remove the load from t...
- 5. Place a 10 gallon (40 liter) container under the vehicle to catch any hydraulic oil that will ...
- NOTE: If a replacement hose is not available, the adjacent boom extend line (1) can be used to re...
- 6. Remove the failed boom retract line (2) from the circuit.
- 7. Remove and temporarily reposition the adjacent boom extend line (1) in place of the failed boo...
- 8. Check the hydraulic oil level and add oil if needed.
- 9. Return to the cab, fasten your seat belt and start the engine.
- 10. Tilt the carriage and/or attachment upward if necessary for clearance before retracting the b...
- 11. SLOWLY RETRACT the boom.
- 12. SLOWLY LOWER the boom and ground the carriage and/or attachment.
- 13. Completely remove the load from the carriage and/or attachment if you haven’t already done so.
- 14. Have the vehicle serviced immediately.
- 15. Replace any faulty hydraulic lines.
- 16. Return to the cab, fasten your seat belt and start the engine.
- 17. Cycle the extend cylinder several times to bleed air from the system. Check for leaks.
- 18. Transfer the waste oil to a container with a cover and label as used oil. Dispose of properly.
- 19. Recheck the hydraulic oil level. Add if necessary.
- STEP 3
- 1
- Towing A Disabled Vehicle
- General Maintenance
- General Maintenance
- Maintenance Schedule And Checklist
- B. Attachment tilt cylinder pins (2 points)
- C. Boom attachments (all points)
- D. Extend Chain Sheave (1 point)
- E. Retract Chain Sheave (1 point)
- F. Hydraulic cylinder pins (12 points)
- G. Drive shaft slip joints (3 points)
- H. Boom pivot pin (2 points)
- I. Axle U-Joints (8 points)
- J. Axle pivot pins (2 points)
- K. Extend cylinder pins (2 points)
- NOTE: Shorten the lubrication interval on all lube points when operating in severe conditions.
- Lubrication Points
- 2. Air Cleaner And Restriction Indicator
- A. Filter Check
- B. Element: Change
- 1. Pull the air cleaner cover lock (1) OUT, turn the air cleaner cover (2) counterclockwise and r...
- 2. Remove the primary element (4). Inspect the element for damage. Damaged elements should not be...
- 3. Thoroughly clean the interior of the air filter canister (5) and vacuator valve (6).
- 4. If replacing the inner element (7) at this time, carefully slide the element out. Always disca...
- 5. Slide the new primary element over the inner element making sure the sealing edge is flush wit...
- 6. Position the canister cover (8) in place, turn clockwise to lock into position and secure in p...
- C. Air Intake System-Inspection
- A. Engine Coolant Level Check
- B. Drain And Flush Radiator
- 2
- NOTE: Use the hose attached to the petcock to allow draining directly into a container.
- NOTE: On vehicles equipped with a cab heater option, a shut off valve is installed at the engine ...
- 6. Transfer the coolant into a properly labelled container. Dispose of properly.
- 7. Reconnect line to bottom of overflow bottle and close petcock on the radiator. Reconnect heate...
- 8. Fill radiator completely with 50/50 mixture of ethylene glycol and water. Total System Capacit...
- 9. Clean dirt and debris from radiator fins and core, if required.
- 10. Start engine and run vehicle to normal operating temperature and then shut OFF the engine. Wh...
- 11. Allow engine to cool to ambient temperature. Check radiator coolant level and top off complet...
- 12. Overflow bottle should be 1/4 to 1/2 full. If it is not, add coolant to overflow bottle. Clos...
- 4. Engine Oil And Filter
- A. Oil Level Check
- 1. Level the vehicle, raise the boom up to approximately 20˚, place the travel select lever in (N...
- 2. Unlock and open right rear engine access door.
- 3. Remove dipstick (1). Check the oil mark on dipstick. The oil should be between the full (2) an...
- 4. If oil is low, remove oil fill cap (1) and add 15W40 motor oil that at least meets the manufac...
- B. Oil And Filter Change
- 1. Operate the engine until warm (approximately 5 minutes).
- 2. Level the vehicle,raise the boom up to approximately 20˚, place the travel select lever in (N)...
- 3. Place receptacle under engine oil pan drain plug (4).
- 4. Remove the drain plug (4) and drain the oil from the engine oil pan.
- 5. Allow oil to drain completely into a receptacle. Transfer the oil to a container with a cover ...
- 6. Unlock and open the left engine access door. Remove oil filter (5). A strap or chain filter wr...
- 7. Clean filter sealing surface. Make sure the o-ring seal from the filter comes off the sealing ...
- NOTE: The filter o-ring may stick to the filter head. Make sure the old o-ring is removed before ...
- 8. Apply a thin coat of clean engine oil to seal on new filter.
- 9. Install the new oil filter and hand tighten 1/2 turn after initial contact.
- 10. Install the drain plug (1) into the oil pan and tighten securely.
- 11. Unlock and open right side engine access door.
- 12. Remove oil fill cap (2) and add 15W40 motor oil that at least meets the manufacturers minimum...
- 13. Reinstall the oil fill cap (2). Start engine and run for several minutes.
- 14. Stop engine. Let the oil drain back for a few minutes. Check oil level on dipstick (3) and ch...
- 15. Add oil to bring oil level up to the FULL mark in the crosshatched area. Replace dipstick and...
- 5. Engine Fuel System
- A. Drain Water From Fuel Water Separator/Filter
- B. Change Fuel Filter
- 1. Unlock and open the right rear engine access door.
- 2. Clean around the fuel filter head (2).
- 3. Unscrew the fuel filter and dispose of properly.
- 4. Clean the gasket surface of the filter head and replace the o-ring.
- 5. Fill the new fuel filter with clean No. 2 diesel fuel.
- 6. Lubricate the o-ring seal with clean No. 2 diesel fuel.
- 7. Install the fuel-filled filter and hand tighten. DO NOT overtighten.
- NOTE: Mechanical over-tightening may distort the threads or damage the sealing ring.
- C. Replace In-line Fuel Strainer
- 1. Unlock and open the right engine access door.
- 2. The in-line fuel strainer (3) is located down line from the engines lift pump (4). Loosen the ...
- 3. Remove the old in-line fuel strainer and dispose of properly.
- 4. Install the new in-line fuel strainer with arrow (6) pointing toward the lift pump.
- 5. Assemble the hoses to the in-line fuel strainer and tighten the hose clamps.
- 6. Remove air from the fuel system (see “Bleeding Fuel System” on page126).
- 7. Close and lock the right engine access door.
- D. Bleeding Fuel System
- 2
- 1. To vent the high pressure fuel lines (4), loosen one fitting (5) at the injector (6).
- 2. Turn the ignition key to the START position and crank the engine for a maximum of 15 seconds o...
- 3. Tighten the fitting. Torque to 22 lb-ft (30 Nm).
- 4. Repeat Steps 1-3 for each fitting until the engine runs smoothly.
- 5. With the engine running, visually check for leaks. Turn ignition switch OFF.
- 6. Engine Fan Belt
- A. Engine Fan Belt Check
- 1. Ground the carriage, place the travel select lever in (N) NEUTRAL, move the neutral lock lever...
- 2. Unlock and open the left engine access door.
- 3. Inspect the fan belt (1). Replace if cracked or frayed.
- 4. This engine is equipped with an automatic belt tensioner (2). Inspect the tensioner bearing. S...
- 5. Spin the fan and check for wobble or excessive play. Maximum play should be .006 inch (0,15 mm).
- 6. To install the fan belt (1); first position the belt over the fan pulley (3), crankshaft pulle...
- 7. Close and lock the left engine access door.
- 7. Hydraulic Oil and Filter
- A. Hydraulic System Oil
- ISO Grade 46 Hydraulic Oil
- MIL-L-2104C 10W Motor Oil*
- Gulf Harmony 46 AW
- Amoco Rykon 46
- Mobil DTE-25
- Arco Duro AW S-215
- Shell Tullus 46
- Benz Petraulic 46-7C
- Sun Sunvis 821 WR
- Chevron AW 46
- Texaco Rando HD 46
- Citgo Pacemaker XD-46
- Castrol Deusol CRD
- Esso Essolube D-3HP
- Esso Essolube XD-3
- Castrol Agricastrol HDD
- Shell Rimula CT
- Shell Rimula X
- Shell Rimula TX
- * 5W20 Motor Oil may be substituted for -30˚ F to 70˚ F (-34 to 21˚ C) only
- B. Hydraulic Oil Level Check
- 1. Be sure all cylinders are fully retracted and oil is at room temperature.
- 2. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, move the neu...
- 3. Check level of hydraulic oil in tank at the sight gauge (1) on the back side of the hydraulic ...
- 4. The oil level should be visible in the gauge window.
- 5. If it is not, add ISO-46 or MIL-L-2104C oil (see table on page129).
- a. Remove the four capscrews (3) holding the hydraulic oil tank cover (4) to the tank, remove the...
- b. Turn the hydraulic oil cap (5) and remove from the filler neck. Add hydraulic oil as needed. T...
- C. Hydraulic Oil & Filter Change
- (Filter Only)
- 1. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, move the neu...
- 2. Fully retract all cylinders and shut OFF the engine.
- 3. Remove the four capscrews (3) holding the hydraulic oil tank cover (4) to the tank (2), remove...
- 4. Clean area around filter head (1). Loosen but do not remove the nuts that secure the filter he...
- 5. Rotate and remove the filter head (1).
- 6. Remove the seal (3) and the element (4) from the filter head (1). Dispose of properly.
- 7. Clean the filter head sealing surfaces.
- 8. Place a receptacle under the hydraulic reservoir magnetic drain plug. The receptacle must be l...
- 9. Re-install magnetic drain plug into the reservoir.
- 10. Re-install the top seal (3) and push a new filter element (4) all the way onto the filter hea...
- 11. Remove reservoir cap (5) and fill the reservoir with ISO-46 or MILL2104C Oil (see table on ...
- 12. Reassemble the hydraulic oil tank cover and tighten the hardware securely.
- 13. Run vehicle and operate all hydraulic functions. Cycle all modes of controls to purge air fro...
- 14. Check for leaks.
- 8. Transmission Oil and Filter
- (Filter Only)
- B. Hydraulic Oil Level Check
- APPROVED UNIVERSAL TRACTOR FLUIDS
- JOHN DEERE
- FORD / NEW HOLLAND
- MASSEY FERGUSON
- CHEVRON
- JDM J20C (HY-GARD)
- ESN-M2C134-D (HYDRAULIC OIL134)
- M-1141 (PERMATRAN III)
- CHEVRON 1000 THF
- A. Transmission Oil Level Check
- 1. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, move neutral...
- 2. Check oil level with engine running at idle and oil at normal operating temperature.
- 3. Remove transmission dipstick (6) through access hole (7) in transmission covers (8) and check ...
- 4. Add Universal Tractor Fluid to transmission as required to bring up to full mark.
- B. Transmission Oil & Filter Change
- (Filter Only)
- 1. Level the vehicle, ground the carriage, place travel select lever in (N) NEUTRAL, move neutral...
- 2. Remove the six hex nuts (1) securing the transmission covers (2) to the frame. Remove the covers.
- 3. Allow the transmission to cool.
- 4. Place a receptacle under the transmission drain plug (3). Remove the drain plug and allow the ...
- 5. Clean and re-install the drain plug (3) into the transmission housing.
- 6. Remove the filter (4) from the filter mount on the front side of the transmission (5). Dispose...
- 7. Apply a thin film of clean Universal Tractor Fluid to the new filter gasket. Carefully install...
- 8. Remove the dipstick (6) and fill with Universal Tractor Fluid approximately 2.6 gallons (9,8 l...
- 9. Check the transmission level and add Universal Tractor Fluid as required following the procedu...
- 10. Reassemble the transmission covers (2) and secure in place with the six hex nuts (1), washers...
- 9. Axle Oil
- (Filter Only)
- A. Axle Oil Level Check
- A. Transmission Oil Level Check
- APPROVED UNIVERSAL TRACTOR FLUIDS
- JOHN DEERE
- FORD / NEW HOLLAND
- MASSEY FERGUSON
- CHEVRON
- JDM J20C (HY-GARD)
- ESN-M2C134-D (HYDRAULIC OIL134)
- M-1141 (PERMATRAN III)
- CHEVRON 1000 THF
- 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neu...
- 2. Clean the area around the axle fill plug (1) and the axle level plugs (2) and remove the plugs...
- 3. Add Universal Tractor Fluid to bring the oil level up and even with the plug holes. See chart ...
- 4. Re-install the axle fill plug (1) and the axle level plugs (2).
- B. Axle Oil Change
- NOTE: At the 1000 Hour Interval Oil Change also inspect the brake disk wear. Refer to “Brake Disk...
- 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neu...
- 2. Clean the area around the axle drain plug (3), the axle fill plug (1) and the axle level plugs...
- 3. Place a receptacle under the axle drain plug. Remove the plug from the axle housing and allow ...
- 4. Transfer the oil to a container with a cover and label the container as used oil. Dispose of p...
- 5. Clean off the axle drain plug (3) and re-install. Remove the axle fill plug (1) and the axle l...
- 6. Fill the axle with Universal Tractor Fluid through the axle fill hole (1) until the oil level ...
- 7. Reassemble the level plugs (2) using new o-rings.
- 8. Re-install the axle fill (1) and axle level plugs (2) into axle housing.
- 10. Brake Disk Inspection
- NOTE: At the 1000 Hour Interval Oil Change also inspect the brake disk wear. Refer to “Brake Disk...
- A. Brake Disk Wear Check
- (1000 Hour Intervals)
- A. Front Axle
- 1. Block all four wheels to help prevent the vehicle from moving after the parking brake is disab...
- 2. Remove the six hex nuts (1) securing the transmission covers (2) to the frame. Remove the covers.
- 3. Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port (3) on th...
- 4. Turn the key switch to the ON position (with the engine not running), release the park brake (...
- 5. Pressurize the park brake with the pressurizing unit. Close the pump needle valve on the press...
- 6. Working through the level plug hole (1), carefully use a screwdriver to spread the brake disks...
- A. Front Axle
- (1000 Hour Intervals)
- 1
- 3
- APPROVED UNIVERSAL TRACTOR FLUIDS
- JOHN DEERE
- FORD / NEW HOLLAND
- MASSEY FERGUSON
- CHEVRON
- JDM J20C (HY-GARD)
- ESN-M2C134-D (HYDRAULIC OIL134)
- M-1141 (PERMATRAN III)
- CHEVRON 1000 THF
- A. Wheel End Oil Level Check
- 1. Position the vehicle on level ground, move the vehicle forward or backward enough to ensure th...
- 2. Ground the carriage, place the travel select lever in (N) NEUTRAL, move neutral lock lever to ...
- 3. Clean the area around the wheel end fill/drain plug (2). Slowly remove the plug. Check the oil...
- 4. Add Universal Tractor Fluid to bring the oil level up and even with the plug hole (2). See the...
- 5. Clean and re-install the wheel end fill/drain plug (2).
- B. Wheel End Oil Change
- 1. Position the vehicle on level ground, move the vehicle forward or backward enough to ensure th...
- 2. Ground the carriage, place the travel select lever in (N) NEUTRAL, move neutral lock lever to ...
- 3. Clean the area around the wheel end fill/drain plug (4). Slowly loosen the plug. Hold a recept...
- 4. Allow the oil to drain completely into the receptacle. Transfer the oil to a container with a ...
- 5. Reposition the vehicle so the wheel end fill/drain plug (2) is positioned horizontally (3).
- 6. Fill the wheel end with Universal Tractor Fluid to the level of the drain plug. See chart of a...
- 7. Clean and re-install the wheel end fill/drain plug (2).
- 12. Wheels and Tires
- A. Tire Air Pressure Check
- B. Wheel Lug Nut Torque Check
- C. Replacing Tires
- 13. Batteries
- 1. Level the vehicle, ground the carriage, place the travel select lever in (N) NEUTRAL, move neu...
- 2. Unlock and open the rear door. The batteries (1) are located inside the frame directly below t...
- 3. Wearing safety glasses, visually inspect the batteries. Check terminals for corrosion. Replace...
- 4. Close and lock rear door
- 13. Batteries
- Battery Electrolyte First Aid:
- Cold Start Grid Heater Fuses
- 1. Unlock and open the left engine access door.
- 2. To access the fuses, open the protective covers (2). Allow the covers to rotate on the tethers...
- 3. Remove the two hex nuts (4) and lockwashers (5) securing the fuse (1) and wires to the fuse ho...
- 4. Place the new fuse and then the wires onto the studs of the holder. Secure the fuse and wires ...
- 5. Snap the protective cover back in place. Be sure the cover snaps securely in place on the holder.
- 6. Close and lock the left side engine access door when complete.
- ECM Fuses and Relay
- 1. Unlock and open the left engine access door.
- 2. Locate the three fuse holders. Remove the clear plastic protective cover (7) from the holder (6).
- 3. Remove the failed fuse from the holder and replace with a new fuse.
- 4. Reassemble the plastic cover onto the fuse holder and securely snap the cover in place. Replac...
- 5. Close and lock the left side engine access door when complete.
- 6. To gain access the relay, unlock and open the right side engine access door. Locate the relay ...
- 15. Boom Chains and Wear Pads
- A. Boom Chain Tension Check
- NOTE: The attachment should remain attached to the quick attach for these checks.
- 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral l...
- 2. Fully extend the boom, then retract it 2" (51 mm) (one inch per section). Turn the vehicle OFF.
- 3. Measure the sag (1) in the top boom extend chains (2) between the bottom of the chains and the...
- 4. Start the vehicle, retract the boom completely and turn the vehicle OFF.
- 5. Go to the back of the vehicle and remove the rear cover from the back of the boom.
- 6. Check the measurement (4) from the top rear edge of the intermediate boom (5) to the top rear ...
- NOTE: If the measurement is less than 8.5" (216 mm) the boom may require extensive adjustment and...
- NOTE: If, by adjusting the retract locknut, you cannot get the measurement within the range of 8....
- NOTE: The attachment should remain attached to the quick attach for these checks.
- B. Top Boom Chain Tension Adjustment
- (As required)
- NOTE: Always perform the “Boom Chain Tension Check” starting on page152 before adjusting the boo...
- 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, move neutral l...
- 2. Adjust the top extend boom chains (1) by tightening the locknuts (3) located at the rear of th...
- 3. Equal chain tension can be checked by the position of the yoke (2) on the outer boom. The fron...
- 4. Start the vehicle and cycle the boom in and out several times. With the boom horizontal, fully...
- 5. Measure the chain sag. Acceptable boom chain sag is between 1.5" (38 mm) and 2.5" (64 mm). If ...
- NOTE: If the top boom extend chain sag cannot be adjusted within the acceptable range of 1.5" (38...
- C. Boom Chain Inspection
- (250 Hour Intervals)
- 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, place the neut...
- 2. Fully extend the boom until the extend chain is taut. Shut the engine off.
- 3. Inspect the retract chains every 1000 hours of operation. Refer to the Service Manual for prop...
- 4. Inspect the chains for the following conditions:
- (250 Hour Intervals)
- A. Wheel End Oil Level Check
- 4
- Storage and Transport
- Storage
- A. Before Storing
- 1. Clean the entire vehicle.
- 2. Lubricate all grease fittings as described in “Lubrication Points” on page110.
- 3. Prepare the engine for storage (refer to the engine manual).
- 4. Apply rust inhibiting lubricant to all exposed hydraulic cylinder rods.
- 5. Disconnect the battery cables. Remove the batteries from the vehicle and store in a dry place ...
- 6. If the ambient temperature is expected to drop below freezing at anytime during the storage pe...
- 7. Preferably, store the vehicle inside where it will remain dry. If it must be stored outside, p...
- B. Removing From Storage
- 1. Reinstall properly charged batteries. Secure the hold-down brackets and attach cables.
- 2. Change the engine oil and filter to remove condensation or other residuals.
- 3. If the vehicle has been stored for two years or more, drain the coolant from the engine block ...
- 4. Wipe off any rust inhibiting lubricant that was applied to vehicles hydraulic cylinder rods pr...
- 5. Refer to “Maintenance Schedule And Checklist” on page105. Perform all the maintenance checks ...
- 6. Review and familiarize yourself and any other operator with all the safe and proper operating ...
- A. Before Storing
- Transport
- Test Procedures
- Stabil-TRAK System Test
- Parking Brake/Transmission De-Clutch Test Procedures
- b. Clear the area in front and behind the vehicle of any obstacles.
- c. Fasten your seat belt.
- d. Turn the key and start the engine.
- e. With the parking brake applied, move the range select lever to (1) FIRST gear.
- f. Move the travel select lever to (F) FORWARD.
- g. Depress the throttle pedal fully. The unit should not move.
- b. Move the travel select lever to (R) REVERSE.
- c. Depress the throttle pedal fully. The unit should not move.
- d. Remove your foot from the throttle pedal.
- e. Move the travel select lever to (N) NEUTRAL.
- b. Move the travel select lever to (F) FORWARD.
- c. Move the unit slowly in a forward direction (approximately 1 mph [1,6 kmh]).
- d. Engage the parking brake. The unit should stop abruptly.
- b. Stop the vehicle using the service brakes, apply the park brake, shift the transmission into N...
- c. Take your foot off the service brake pedal. The vehicle should not move.
- d. Apply the service brakes, shift the transmission into REVERSE (R), move the park brake switch ...
- e. Repeat “Test 3” by backing up the grade and checking the park brake holding performance.
- 1. Immediately remove the vehicle from service.
- 2. Block all four wheels to prevent the vehicle from moving.
- 3. Place the accident prevention tags (1) on the ignition switch (2) and the steering wheel (3).
- 4. Service the parking brake immediately or contact your local Sky Trak Distributor to repair the...
- Four Wheel Steer Indexing Procedure
- 1. With the steering select switch (4) in the Four Wheel Steer position (5), turn the steering wh...
- 2. While holding the steering wheel full left, toggle the steer select switch to the Front Wheel ...
- 3. Toggle the steer select switch back to Four Wheel Steer position (5) and turn the steering whe...
- 4. Toggle the steer select switch back to Front Wheel Steer position (6) and steer the front whee...
- 5. Toggle the switch to the Four Wheel Steer position (5) and return to center.
- Specifications
- Index
- Accident Prevention Tags
| Recognized languages: | English |
|---|---|
| Pages: | 154 |
| Size: | 4.88 MB |
Show table of contents
Document Outline
- 31200749_A_6036 6042 8042 10042 10054 (T4i)_SkyTrak_O&SM
- Revision Log
- Read This First
- Table of Contents
- Section 1 - General Safety Practices
- Section 2 - Pre-Operation and Inspection
- Section 3 - Controls and Indicators
- Section 4 - Operation
- Section 5 - Attachments
- Section 6 - Emergency Procedures
- Section 7 - Lubrication and Maintenance
- Section 8 - Additional Checks
- Section 9 - Specifications
- Index
- Inspection, Maintenance and Repair Log