Genie Square Shooters Series Operator's Manual

OPERATOR'S

236491

MANUAL

SS-624 SS-636 SS-836 SS-842

SS-1048

6/4/97

IiiITEREX HANDLERS

455 N. Superior Ave. Baraga, MI Ph. (906) 353-6675 Fax (906) 353-7543 http://www.sqshooter.com E-mail: bpi@up.net

49908-0248

TABLE OF CONTENTS

SECTION

1 GENERAL

General Safety Procedures...................................................... 1-3

Proper

Safety DecaI............................................................................... 1-9

2 CONTROLS

Cab Enclosure............................................................................ 2-3

Joystick Control Functions..................................................... 2-4

Joystick Control Functions With Button Pushed................... 2-5

Brakes......................................................................................... 2-6

Dash PaneI.................................................................................. 2-7

Gauges........................................................................................ 2-8

Steering....................................................................................... 2-8

Transmission............................................................................. 2-9

Hydraulic Pump........................................................................ 2-9

Differential Lock.......................................................................

Load

SAFETy

Chart

Use............................................................ 1-8

AND

INSTRUMENTS ...................................... .

............................................................... .

1-1

2-1

2-10

3 OPERATION ............................................................................ . 3-1

Operation And Safety Guidelines............................................. 3-3

Before Starting The Engine....................................................... 3-4

Starting The Engine................................................................... 3-8

Before

Operating The 4-Way Controller........................................... 3-14

Operating The Machine With A Load..................................... 3-15

Transporting A Load................................................................. 3-16

Lifting A Load............................................................................ 3-17

Placing A Load........................................................................... 3-18

Retracting From A Load........................................................... 3-22

Operating The Square Shooter.................................... 3-9

SECTION

SECTIONS

4

MAINTENANCE PROCEDURES..........................................

General Safety Practices........................................................... 4-3

(Or

50

Weekly

Six

Month Yearly

Hydraulic System Contamination Prevention........................ 4-28

(Or

MATERIAL SAFETY DATA SHEETS.........................................

Hours) Maintenance........................................ 4-6

(Or

1,000 Hours) Maintenance.............................. 4-14

2,000 Hours) Maintenance.................................... 4-27

4-1

5-1

SECTION

1

GENERAL

SAFETY

1-1

TABLE

OF

CONTENTS

SECTION 1-GENERAL SAFETY:

General Safety Procedures

Proper Load Chart Use

Safety Decal

1-3

1-8

1-9

1-2

GENERAL SAFETY

GENERAL

SAFETY ALERT SYMBOL

Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid personal injury and/or death.

ffiWARNING

Always wear eye protection and personal safety

equipment.

THE OPERATOR

The operator must be fully trained and qualified

to operate this machine.

SAFETY

PROCEDURES

Before start-up or machine operation, the

operator must learn the

the:

1.

controls

2.

instruments

3.

indicator lights

4. safety and instruction labels

location and purpose

ACCIDENT PREVENTION

Use protective clothing and safety equipment.

Always use approved safety equipment such as: gloves, safety boots, safety hard hats/ goggles and ear protection when necessary.

Wear protective clothing that where required.

is

snug and belted

FIRE PREVENTIONIFIRST AID

Install a first-aid kit and fire extinguisher in the operators cab.

of

KEEP THE FIRST-AID KIT EXTINGUISHER properly maintained.

Follow instructions provided with the first-aid

kit and fire extinguisher.

and

FIRE

1-3

GENERAL

SAFETY

GENERAL

SAFETY

WELDING PRECAUTIONS

[LCAUTION

Any unauthorized welding can cause structural failure or possible personal injury. structural member. All unauthorized welding will void the warranty.

DO NOT

weld

on any

HAND HOLDS AND STEPS

[LCAUTION

Slips and falls can cause serious personal injury.

off

When getting on and point contact with the steps and

handrails while facing the machine.

machine, always maintain a three

PROCEDURES

[

DO NOT use steering wheel or any controls

handrails.

NEVER jump on or

of

Be careful steps and handrails when getting on and machine.

Always shut

slippery conditions on platforms,

off

the machine.

engine and set parking brake

off

as

the

BEFORE leaving the operator's station.

REFUELING

[LWARNING

Fires can cause death or severe personal injury.

Handle fuel with care; it

NOT

refuel the machine while smoking or when

near open flame or sparks.

Always stop engine before refueling machine. Fill fuel tank outdoors.

is

highly flammable. DO

Prevent fires by keeping machine clean

grease and debris. Always clean up spilled fuel.

of

trash,

1-4

GENERAL SAFETY

GENERAL

SAFETY

HYDRAULIC SAFETY

[LCAUTION

Hot hydraulic oil can cause severe bums. DO NOT work

if

on the hydraulic system (49°C).

Before ANYONE works on the hydraulic system:

1.

Lower forks to the ground.

2. Engage parking brake.

3.

Shutdown engine.

4. Clean area around oil reservoir cap.

5.

Loosen oil reservoir cap.

6. Remove key from starter switch.

oil temperature exceeds 120° F

FLUIDS UNDER PRESSURE

PROCEDURES

[LCAUTION

Escaping fluid under pressure can penetrate the skin and

cause serious personal injury.

Use a piece leaks. sure system, ensure that all connections are tight. apply pressure to a damaged line, hose or fitting.

If

injured by escaping fluid, see a doctor at once. Proper medical treatment must be administered immediately. A serious infection or reaction can result without proper medical treatment.

of

cardboard or paper to search for

DO NOT use hands. Before disconnecting lines, be

to

relieve all pressure. Before applying pressure to the

DO NOT

SERVICE TIRES SAFELY

An

improperly mounted over-pressurized tire can result in tire explosion causing possible personal injury. An inflation cage or other safety device must be used during tire inflation.

DO NOT attempt to mount a tire unless you have

the proper equipment and experience to perform the job. Have it done by your SQUARE

or qualified repair service.

SHOOTE~

dealer

1-5

GENERAL

SAFETY

GENERAL

SAFETY

USE SEAT BELT

Always wear seat belt while operating the SQUARE SHOOTER®

to reduce the risk

of

personal injury.

PRACTICE SAFE MAINTENANCE

Unauthorized modifications to machine may impair the safety, machine function and/or affect machine life.

AL WAYS

working on, under or around the SQUARE or forks.

DO NOT adjust or oil machine while it

Use

a safety support or brace when

SHOOTER

is

in motion.

PROCEDURES

<

1

~

J:

uI

'::!

""

\.J

v

"2

...

"2

...

I-

c

w

.n

~

<C

E:

SHUT OFF engine and remove key when working on

machine unless maintenance instructions require engine running (see Maintenance Procedures section 4).

REPLACE any shields or guards removed for

servicing.

NEVER use the SQUARE SHOOTER as a platform

for lifting personnel.

BOOM

SAFETY

DO NOT enter DANGER AREA under or around boom

when the forks are (See diagram to the right detailing danger area.)

Serious personal injury could result should unexpectedly drop.

Before

ANY work is performed in the DANGER AREA

the boom must be and the forks must be resting on the ground.

off

the ground while engine

if

boom

COMPLETELY lowered

is

running.

Remove key from start switch to prevent accidental starting.

1-6

GENERAL SAFETY

GENERAL

AVOID ELECTRICAL POWER LINES

&

DANGER

Serious injury electrical lines. NEVER move any part load within (A) length

EXAMPLE: then twice the length is part

of

(3.4m)

or

death can result from contact with

of

the machine or

10

feet (3m) plus twice the line insulator

of

an electric line.

If

the line insulator (A)

12

in. the machine or load should not be within of

the electric line.

is 6 in.

(152 mm),

(305mm). Therefore, any

SAFETY

11

feet

PROCEDURES

&WARNING

Always remain completely inside cab enclosure while

operating the machine.

ffiWARNING

Never operate this machine under the influence

and lor alcohol.

of

drugs

1-7

FEET--'6

UETER--( •.

FEET--

UEITR--( •.

F'EET-24

UmR-(7.32)

,2

8 • 0 • 8

88)(3.66)(2.44)(1.22)

16 12 8

88)(3.B6)(2.44)(,.22)

20

16

(B., 0)(4.88) (3.66) (2.44)(1.22)

...

12

B 4

(1.22)(2.44)(3.66) ( •.

0 4 a

(1.22)(2.44)(3.66)

• B

(,.22)

GENERAL

SAFETY

PROPER LOAD CHART USE

,2

,6

88)

12 16

('.88)

,2 ,6

(2

.••

) (3.86) (4.88)

FEET-24

UmR-(7.32)

40

('2.20)

(1~~B)+-H-t--+-+--17

(.}~)-l-HH-t-7'

(B.S.)

(7.32)

20

(6.

'0)(

H--t+++-H-r

26

2'

,6 ,2

•.

8 4

88) (3.66) (2.44) (1.22)

• 8

(1.22) (2.44) (3.66) (4.88)

(6~~)

,6

(4.86)

,2

(3.66)

B

(2.44)

4

(,.22)

4

(,

.22)

H-'-r-r-r.,--,--r-r1-r-,--.+-l-+-HH-+-+++t

FEET-24

UmR-(7.32)

20

,6

(6.,0)

(4.88) (3.66) (2.44)

,2

8 4

(,

.22)

4 8 12

(1.22)(2.44)(3.66)

,2

,6

16

( • .88)

40

'2.20)

HH-+++-h-Y

,J.~B)-l-HH-t--t-:-I'

(9~~)·-l-HH-V

28

(0.54)

24

(7.32)

(B~~)

,6

(

•.

88)

,2

(3.66)

B

(2.44)

•

(1.22)

•

(,.22),-+-P-,

...

-.

....

..-r-r-,--,-..,---rlH-+++-H-t-++-I

FEET-24

Mrn;R-(7.32) (6.10)(4.88) (3.66)

20

,8

,2

8 •

(2.44)(,

LIFT

CHART I SS-836

SQUARE

(,.22)(2.44)

.22)

CAPACITY

SHOOlER

4 8 12

(3.68) (4.08)

fET-

2B

.rn:R-( ....

(,t."")H-++t-IH+-l-H....y?r-"11

(,t.t2)-l-H-++-H-t--+-h

24 20 18 12 B 4

) (7",2) (

•.

'0)(

....

) (3.66) (

V

......

) (1.22)

('.22)

(,r.O)-l-H-++-H-t-7'

(,~.)+-H+-l-t7

(S}\)+-I-t--t-'f1'

2B

(B.")

2.

(7.32)

20

(8..10)

('~:')

,2

(3.66)

B

(2.44)

•

16

(",.)

(,.h)H..I.,-.,--.,..,...,..,-,--,,-,-.,--,.,r++-l-H-+++-H+i

P'EEI'-32

t«TEJl-(1.75)

(tHa)

(,a._

(1~

(1~)

(,J.t.j

(.~:ii)

(iA)

(7~)

(e~~)

(21.)

~l.)

(2,44)

(11:z)

28

24 20

HI

12

III

"

(&S4)(7.J2)

(6..10)(4.811)

(1M)

(2.44)(1.22)

"'812111120

(1.22) (1.44)

(1U)

(4.88)

(e.l0)

FEEr-

"""'-(

....

28

24

) (7.32) (

2Q

Hi

12

....

) (3.88) (

8 4

..

44) (,.22)

•.

'0)(

('.22)(

The load chart shows how high up and how far in front loads can be safely picked and placed with a properly maintained and operated machine. To use the load chart the operator must know the weight

of

load

the load and how far

is

heavier than stated on the load chart, three options can

1.

Move the machine closer to the load so that the weight

"out"

and "up" it has to

fall within the load chart specifications.

2 Divide the load into smaller pieces so that each piece falls into load

chart specifications.

it

•

3.

Get a larger machine that can handle the load within specifications.

WARNING

NEVER raise a load and drive to position it. This can cause the machine to turnover. When placing a load, always move the machine with the load and the boom horizontal or lower. When the machine close

as

(,J,)8~cl~p+L1:I+=q:Il=I£E±E±:teB

FfET"-.32

METER-(1.7&)

28

24

(&lJ4.)('7.32)

20

16 12

(1.10) (4.B8)

e 4 4 a 12

(3.")

(2..44)(1.22) (1.22) (2M.) (3.8fi) (UB)(a.10)

HI

20

possible to where the load needs to

brake, raise the load, then place the load into position.

be

placed, set the parking

1-8

4-

B 12 16 20

(2.44)

(3.,,) ( ....

04-

8

12

......

)(3

...

) (

of

the tires various

be

placed.

If

be

used.

of

the load will

is

H

•.

'O

HI

20

....

)(

•.

'0

the

as

GENERAL

SAFETY

YOUR

W'EfY

JUDGEMENT 1LL

1lIE

TO YOU

DO

(15.24

~

USED

IUlAYS

CAN

ABSWIIUY

IN

CONIROl.S

SPEED.

BIWONG,

OPERATE.

KNOW

n£

NOT

OPERATE

y)

......

1NJtJR'1'

Ia

A

GUIDEUNE

RaNt

~

SERIOUS

NO

AND

THE

11£

OPERATION

BEFORE

SIEERNG.

REID

THE

LUrA11ONS.

SQUARE

RADIUS.

OR

PROPERTY

COMPlElUY

PERSOtW.

RIDERS

SAFETY

W'EfY

OF

ATI'EMP1IG

OPERATORS"

AND

ON

'DIS

All)

SHOC7IER

FIUIIG

rwu.GE.

SHOUlD

wmtN

INJURY.

w.cHINE

ntOSE

EQUFNENT.

TO

OPERATE.

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IWflW..

TRIaOR

OBJECI'S

'DIS

lIE

ENIJ,RGEJ)

~

OR

ATTACIIE«.

DECAL

AROUfI)

YOU

KNOW

1LL

aww:TERIS1lCS

EQlIFMt)lF'

All)

IS(

QUESTIONS

WtII.E

PEOPLE

FROM

1l£

50

FOOJ'

(15.24

F

WMIWITED

ENC.OSURE

DEPENDS

11£

POSITIONS

OF

lHE

AND

FORICS

OR

II)

WHILE

OPERATING

UPON

YOUR

Nfl

Hi\S

LUrAlIONS.

MIQINE

OF

YOUR

PROPERTY

ATTACHUENJ'

.......

BY

RADIUS

WORKING

WOINE.

USING

CME

FUNCTIONS

UNDERSrAND

BEFORE

SUPEIMSOR

ARE

srARTINC

wmf/N

CAN

CAUSE

SHOUlD

00NDfII0NS.

FMlING

All)

OF

UN11U.

A 50

lIE

DEBRIS

FOOT

NEYER

LOWER A MAXMIM

~

INJURY

N..WAYS

WE'AR

H..WAYS

INSPECf

OR

NMltINC

SO

CAN

CAUSE

DO

NOT

TRA'tfl.

TIP

<M:R.

IUlAYS

I.E'tU.

1HE

BOOM

OR

~AY

lHE

WfIH

DrAm

CON11tOI..

'SIIAY

INJURY

USE USING

CAUSE

OR

!)£Ant

1liE

SE'AT

1l£

.w:HINE

OUT

OF

1l£

INJURY

ON

TERIWN

1l£

IiWH£

Nt

UNl.f.VEl.

TO

CON1ROl

MttICHINE

TO

I.CW)

BEfORE

COULD

OCCUR.

BELT

WHE'Jt

DM.Y.

~.

OR

DE'AlH.

OR

It

IS

INDICATED

IUOINE

ll:VEL

ll£

t.W:HI£

WHEN

n£

OYERI'URN

~

Baraga

BOX

248 /

RETRICIING

OPERATING

CHCK

REPAIR

lWIGEROUS

OH

YAY

BOOM

1liE

FOR

AII)/OR

MEJS

n£

CAUSE

WHEN

IS

HIGHER

INJURY

IT.

.w:HIHE

.w:HINE.

MISSING

REPI.J.CE

~T

GAUGE

ll£

watNE

ll£

BOOM

nwt

OR

DrAlH.

GUt.RDS

BEFORE

Productsl Inc.

BARAGA.

MI.

49908

TURN

NID

MlEDlAlaY.

cotI.D

IWSINC

TO

POSITION

1HE

HORIZOHTIL.

IM:R.

sa&NS.

FM.URE

CAUSE

ll£

0't'ERTURN

IS

HORIZOHTIL.

CONPONENT

LOOSE

BOlTS,

TO

DO

WQINE

BOOM.

CMJSING

POSI11ON

TO

RAISING

OR

MAY

LOWER.

3-1218

1-9

GENERAL SAFETY

NOTES

1-10

SECTION 2

CONTROLS AND INSTRUMENTS

2-1

TABLE

OF

CONTENTS

SECTION 2- CONTROLS AND INSTRUMENTS:

Cab Enclosure

Joystick Control Functions 2-4

Joystick Control Functions With Button

Brakes 2-6

Panel

Dash

Gauges 2-8

Steering

Transmission 2-9

Hydraulic

Differential Lock

Pump 2-9

Pushed

2-3

2-5

2-

7

2-8

2-10

2-2

10--+-

CONTROLS

CAB ENCLOSURE

17

18 15

13

""""=---_1-J~---

AND

12

INSTRUMENTS

14

9

6

1

SS-1048

~oooto

ooog~

1 1 1 1

20--H-~

8

7--+-1l

2

3

4

5

6

~-t----l1

1.

Accelerator Pedal

2. Joystick Controller

3.

Square Shoot Activator Button (Opt)

4.

Gear Selector

5.

Forward/Reverse Selector

6.

Steering Selector

7.

Parking Brake

8.

Service Brake

9.

Parking Brake Warning Light

10.

Load Chart

11. Warning Decal

12.

Gauges

l3. Machine Level Gauge

14.

Fuse Holders

15.

Headlight Switch (Opt)

16.

Frame Sway Controller

17.

Pump Destroke Button

18.

Fork Frame Sway Controller (Opt)

19.

Stabilizer Switches (SS-l 048)

20.

Differential Lock (SS-1 048,SS-842)

17

18

19

16

I

15

2-3

CONTROLS

JOYSTICK CONTROL FUNCTIONS

AND

INSTRUMENTS

Use the joystick control lever to operate boom and forks follows:

A

-Boom

B - Boom Up

Down

as

B

A

C -Boom Out

D -Boom In

E - Boom Down and Out

F - Boom Up and In

G - Boom Up and Out

H - Boom Down and In

E

c

2-4

CONTROLS

JOYSTICK CONTROL FUNCTIONS (WITH BUTTON PUSHED)

AND

INSTRUMENTS

With button on top

movement the following:

A- Tilt out.

B- Tilt in.

of

the joystick changes functions to

of

joystick depressed the

(~B

,

A

C - (Optional) Square Shoot Out

D- (Optional) Square Shoot In

2-5

CONTROLS

AND

BRAKES

INSTRUMENTS

The brake pedal the service brakes. vates service brakes on all four wheels.

The brake should be applied during nonnal operation to stop machine movement.

On machines equipped with rear-lock cylinders models

activate the cylinders into the lockup mode.

(SS-1048 and SS-842) the service brakes will

is

the operator control for

Pushing pedal (A) acti-

ffi

WARNING

Failure to set parking brake before leaving machine may result in unintended machine movement and possible

injury, death, and/or damage to machine or property.

The parking brake (B) should be engaged

anytime the operator gets To engage, lift handle straight up until it "locks" over center.

ffi

Always disengage parking brake before attempting to move machine. To disengage push handle (B) down until it completely collapsed. Failure to disengage parking brake

during operation can cause parking brake failure. Heat build

up from an engaged parking brake may cause a fire.

off

the machine.

CAUTION

is

(B)

2-6

CONTROLS

AND

DASH PANEL

& WARNING

Always ensure that machine level indicator before raising the boom. Raising boom with a unlevel machine may cause the machine to overturn, resulting in

injury or death.

is

at zero

(0)

INSTRUMENTS

F

E

& WARNING

Use frame sway control to level machine only when the boom position control when boom cause machine to overturn, resulting in injury or death.

1.

FRAME SWAY CONTROL

The frame sway control (E) panel. The frame sway control with the machine level indicator

of

the dash panel. The sway control lever

the left or right depending on the particular requirement.

2. ROTATING

The rotating fork frame control (G) located on the

dash panel allows the operator to position forks

for insertion or removal from pallet.

NOTE: The rotating fork frame

machine

no control will be mounted on the dash panel.

3. HEADLIGHT SWITCH

The head light switch (H)

This

is

a push/pull type switch.

is

horizontal or lower. Using frame sway

is

higher than a horizontal position may

is

located on the dash

is

used in conjunction

(F) mounted on top

is

either moved to

FORK FRAME CONTROL

is

an option.

is

not equipped with a rotating fork frame,

is

located on the dash panel.

If

your

'c:r::::::::a:::

H

1

•

NOTE: Head lights are optional.

is

not equipped with headlights, no switch will be

mounted on the dash panel.

3.

PUMP DESTROKE CONTROL The pump de stroke button (J) panel.

4.

FRONT STABILIZER CONTROL The front stabilizer switches (K) are located on the dash panel

just to the left

NOTE: The front stabilizer switches are standard equipment

on the SS-1048.

of

the frame sway control switch.

If

your machine

is

located on the dash

2-7

r=-.:;:c---j

+ +

'---------'

I--....l......----,--j

CONTROLS

The following gauges are used to monitor the machine:

A - Fuel Level

AND

GAUGES

INSTRUMENTS

000

00 00

B -

Oil Temperature, Powershift Transmission

Oil Pressure, Powershift Transmission

C -

D - Voltmeter

E - Water Temperature, Engine

F - Oil Pressure, Engine

STEERING

LLCAUTION

Before changing steering selections, make sure all four wheels are in line. Failure to align wheels to proper settings before changing steering positions may cause haphazard steering. This may result in injury to personnel and/or damage to machine or property.

In addition to the steering wheel, located front

of

the operator, the SQUARE SHOOTER has another

steering control, the steering selector valve.

directp

in

00G

reo

D

oe

~OOOlOO

ooog~

l' • " l'

The Steering Selector valve valve. The positions accurate shifting. The three positions are: 4-wheel, 2-wheel, and oblique. Valve positions are selected and function as follows:

4-WHEEL is selected when valve is in far right position.

In 4-wheel mode rear tires follow the same track as front tires.

2-WHEEL is selected when valve

In 2-wheel mode only front wheels tum.

OBLIQUE is selected when valve is in far left position.

In oblique, also known as

wheels

tum

in the same direction.

(C) is a three-position

of

the valve have detents for

is

in center position.

"crab" steering, all four

2-8

l-=:;:.L----1

+ +

'----------'

2 wheel

1---'----,----1

CONTROLS

AND

TRANSMISSION

1.

TRANSMISSION RANGE CONTROL The transmission range control (A) has three selections,

first, second and third. First Second speed, low torque. This allows operator to select speed and torque range most suited for the job being performed.

2.

FORWARD/REVERSE SELECTOR VALVE

The forward and reverse selection control (B) has three positions: F (Forward), N (Neutral), and R (Reverse). Because the machine switch, this lever must be in the neutral position before starting the machine.

is

medium speed, medium torque. Third

is

low speed, high torque.

is

equipped with a neutral start

is

high

INSTRUMENTS

D

~OOO]gg

0000.

'IT'

• 0

'IT'

.....

B

-+--A

HYDRAULIC PUMP

&

DANGER

Depressing pump de stroke button while operating the SQUARE loss ous situation. Hydraulic functions that will be affected are: STEERING, and RETRACT, OPTIONS. as

the button

tion

The pump destroke button will be the black push button switch located on dash panel.

NOTE: button will be located directly to the left

SHOOTER®

of

hydraulic power, possibly creating a very danger-

None

is

if

accumulator backup has a sufficient gas charge.

On machines equipped with front stabilizers the

will cause an immediate

FORK TILT, LIFT, BOOM EXTENDED,

SWAY and ALL HYDRAULIC

of

these functions will operate

depressed. Brakes will continue to func-

of

the dash panel.

as

long

+

L-

____

000

OOC)

l • 0

---------~

+I----'------,------.j

--'

o

C)

00

o.

For example, when starting machine for the first time

300day, depress pump de stroke button while

on a starting engine. Continue to depress button for seconds after engine starts. Once engine smoothly, release button and the hydraulic pump will engage. DepreSSing pump de stroke button will not be required for

all other starts

to cool completely.

of

the day, unless engine has been allowed

is

15

running

to 20

2-9

CONTROLS

AND

DIFFERENTIAL LOCK

IMPORTANT Before engaging the front axle differen-

tiallock, make sure the wheels come to a complete stop. Failure to do so will result in premature wear components.

of

internal

INSTRUMENTS

D-~~I

Models differential lock and push button (D). This foot operated push button is located directly to the left pedal.

Depressing and holding the differential lock push button

(D) locks the front axle into a positive traction mode.

SS-1048 & SS-842 are equipped with a front axle

of

the service brake

l-=-'?-----i

+ +

L-

____

f----'----r----J

---'

2-10

CONTROLS

AND

NOTES

INSTRUMENTS

2-11

SECTION 3

OPERATION

3-1

TABLE

OF

CONTENTS

SECTION 3- OPERATION:

Operation And Safety Guidelines

Before Starting The Engine

Starting The Engine

Before Operating The Square Shooter

Operating The Four Way Controller

Operating The Machine With A Load

Transporting A Load

Lifting A Load

Placing A Load

Retracting From A Load

3-3

3-4

3-8

3-9

3-14

3-15

3-17

3-18

3-22

3-2

OPERATION

AND SAFETY GUIDELINES

LLWARNING

Your safety and the safety equipment. Know the positions and functions Understand the speed, braking, steering, stability, and load chart characteristics the Operator's Manual and ask questions read, fully understand, and follow these operation and safety guidelines.

1.

DO

NOT

operate SQUARE SHOOTEJt tractor while people and radius. Falling objects from the forks or attachment can cause property damage and/or serious personal injury. This 50 foot (15.24 m) minimum radius should be used only as a guideline. Enlarge minimum working area working conditions.

2.

ALWAYS remain completely within the cab enclosure while operating machine. Falling debris can cause serious personal injury or death.

3.

NEVER occur.

4.

ABSOLUTELYNORIDERSSHOULDBEALLOWEDONMACHINEORATIACHMENTS.

5.

NEVER occur.

6.

INSPECT

obstructions cannot be cleared, mark obstructions with a stake or other marker that will be clearly visible to the operator.

7.

DO pressurized coolant.

S.

AL

9.

ALWAYS inspect the machine daily. Check for leaks, worn hoses, loose belts, or anything out and/or replace any

10.

CHECK

11.

CHECK start safety switch,back alarm,horn, and always make sure mirror is adjusted properly.

12.

DO

13.

DO

14.

CARRY A LOAD

15.

ALWAYS level machine an unlevel machine may cause machine to overturn causing injury or death.

16.

USE frame sway control to level the machine only when the boom position

sway control when the boom death.

17.

DO

cold start-ups. Depressing the button while operating a lic power that will affect steering, fork tilt, lift, boom extend and retract, sway and all other hydraulic functions. Brakes will continue to function

extend a load beyond the load chart band. Machine

lower a maximum load before retracting

and clear working area

NOT

check engine coolant level

WAYS wear seat belt when operating machine.

worn, to be sure that all guards and screens are secure and in the proper place. to be sure that all safety devices are functioning properly: parking brake, service brake,level gauge,neutral

NOT

travel on terrain or in dangerous areas that could cause machine to tip over.

NOT

attempt to start engine by towing or pushing. Damage to the powershift transmission could result.

so that you have maximum machine stability and visibilty is not obstructed.

NOT

depress the pump destroke button while operating the machine. This button should be used only during

of

those around you depends upon your using care and judgement in the operation

of

all controls before attempting to operate. All equipment has limitations.

of

the machine before operating. Read

of

your supervisor until you know machine limitations.

lor

property are within a 50 foot (15.24 m) minimum

tum

over, component damage, injury or death could

it.

Machine tum over, component damage, injury or death could

of

any obstructions (rocks, fence, wire, etc.) that could cause machine damage.

if

engine has recently been run. Injury could occur from escaping hot

damaged or leaking parts immediately. Failure to do so can cause injury or death.

as

indicated on the machine level indicator; before raising boom. Raising the boom with

is

horizontal or lower. Using the frame

is

higher then a horizontal position may cause the machine to overturn causing injury or

SQUARE SHOOTER will cause an immediate loss ofhydrau-

if

accumulator backup has a sufficient gas charge.

It

is very important to

if

warranted by

of

the ordinary. Repair

of

this

If

3-3

OPERATION

BEFORE STARTING THE ENGINE

The following procedures should be performed before

starting the engine.

ffiWARNING

Do not perform any procedures in this section, " BEFORE STARTING THE ENGINE" , unless machine off

and engine is cool. Failure to do so

injury, death or damage to equipment.

1.

Walk around machine and check for any parts that are missing, worn, damaged or leaking. Repair and! or replace damaged parts.

may

result in serious

is

2.

Check engine oil level. Iflow, add 15w40 motor oil that is

API code CD/SC, or seasonal weight recommenda-

tion. Contact your SQUARE SHOOTER dealer for more information.

®

3-4

OPERATION

BEFORE STARTING THE ENGINE

& WARNING

Do not check coolant level Injury may occur from hot escaping pressurized coolant.

3.

With engine cool, check engine coolant level.

When checking coolant level, coolant should be visible

of

in top tank add a

50/50 mixture

freeze/coolant.

radiator.

if

engine has recently been run.

If

coolant

of

water and glycol- based anti

is

not visible

3-5

OPERATION

BEFORE STARTING THE ENGINE

4.

Open water drain plug. Place empty container under drain plug located at bottom present, leave plug open until fuel starts to flow out plug. Close drain plug. Clean up any fuel on the machine or the ground. Dispose

of

fuel filter.

of

If

properly.

water

is

of

5.

Check hydraulic oil level sight gauge. With boom down and retracted and SQUARE SHOOTER level, the sight gauge should read low, fill hydraulic reservoir with Amoco 1000 or equivalent tractor fluid. Hydraulic reservoir fill is located

directly below main pivot ofboom.

112

full. Ifhydraulic oil level

®

is

3-6

OPERATION

BEFORE STARTING THE ENGINE

6.

Remove back cover from air cleaner. Remove and inspect air cleaner. Thoroughly clean inside filter on

NOTE: Two filters required on turbo- charged

machines.

if

required.

of

the canister. Replace

7.

Grease the following components daily: A. Both axle pivots - plumbed out to the side

the machine.

B. Both ends

c.

The fork frame mounting pin.

D. Both ends

of

the lift cylinders.

of

the fork tilt cylinders.

SEE LUBE CHART ON PAGES 4-12&13

of

3-7

OPERATION

STARTING THE ENGINE

ffiDANGER

Any problems discovered in steps 1 thru 8 should be ® documented and corrected before this SQUARE SHOOTER

is operated.

ffiDANGER

If

machine should start with transmission control lever in

gear, stop operation at once. Property damage, serious

injury or death may occur to material and personnel around machine at time technician repair machine.

of

engine start. Have a qualified service

1.

Place transmission control lever in neutral. SQUARE SHOOTERS are equipped with a neutral start safety switch to prevent engine from starting with transmission in gear.

2.

Insert ignition key in ignition switch. Rotate clockwise until engine starts. Release key when engine starts.

ffiCAUTION

If

engine fails to start within 30 seconds release key ,wait at least 2 minutes to allow starter motor to cool before trying again.

If

engine fails to start after four attempts,trouble shoot and correct problem. For more information on troubleshooting contact your local SQUARE SHOOTER dealer.

DO NOT

This may cause damage to starting motor.

tum

key in ignition while engine

is

running.

ffiCAUTION

Attempting to start engine by towing or pushing machine will result in damage to powershift transmission and will not start engine! personnel injury.

It

also

is

a unsafe practice that could cause

3-8

OPERATION

BEFORE OPERATING THE SQUARE SHOOTER®

1.

Check dash-mounted gauges for logical readings. For example, on a cold start-up with engine at low idle, readings should be as follows:

• Engine oil pressure, 40 PSI or more

• Voltmeter,

• Transmission oil pressure, 180 PSI or more

• Fuel tank, at least

12

volts or more

112

full

2.

Operate joystick controller momentarily in all directions. Refer to listings and associated drawings on this page to determine direction ofmovement:

· Joystick forward, in position A, lowers boom

· Joystick backward, in position B, raises boom

· Joystick right, in position C, extends boom

· Joystick left, in position D, retracts boom

· Joystick in position E, lowers and extends boom

· Joystick in position F, raises and retracts boom

· Joystick in position G, raises and extends boom

· Joystick in position H, lowers and retracts boom

The following movements can only be accomplished with the

joystick controller button depressed. This button

on the top

of

the joystick controller.

· Button depressed with joystick in position A tilts the fork frame forward.

· Button depressed with joystick in position B tilts the fork frame back.

· Button depressed with joystick in position C Square Shoots out (optional feature;

· Button depressed with joystick in position D Square Shoots in (optional feature; nla SS-624)

n/a SS-624)

is

located

STANDARD JOYSTICK FUNCTIONS

A A - Boom Down

r-~;=.-

\

n

i

, ,--- - --

.-'--

BUTTON DEPRESS JOYSTICK FUNCTIONS

D-m~

,',

l E

"I

I

I'

,I

;.1

\ i i

________ . .1 B : - oom

A.

Tilt Out

B.

Tilt In

: . " C D - Boom

I'

t,

i 1 i E - Boom Down

-..

I G F

____

--'1

:::::~"

I

BUd

G - Boom

H - Boom Down

C.

Square Shoot Out

D.

Square Shoot

In

Up

pan

In

and

I

n

Out

In

3-9

OPERATION

BEFORE OPERATING THE SQUARE SHOOTER®

3.

Operate frame sway control momentarily.

The black ball in level indicator moves in same

direction as sway control lever. The

SHOOTEt'tilts sway control. For example, moving sway control to the left tilts machine to the left. Moving sway

control to the right tilts machine to the right.

in the same direction as the

SQUARE

4.

Check steering operation by turning steering wheel

approximately one-quarter

and rear tires are not aligned properly, move steering

selector valve to

into alignment with rear tires.

valve back into

"2-wheel" position. Bring front tires

"4-wheel" position.

tum

in each direction.

Place steering selector

If

front

3-10

OPERATION

BEFORE OPERATING THE SQUARE SHOOTER®

& CAUTION

Operating SQUARE SHOOTER with parking brake engaged can cause brake failure. Heat build up from brake being engaged can cause a fire.

& DANGER

Ifmachine does not stop immediately when brake pedal is applied, do not use SQUARE problem before using this machine. Failure to follow this procedure may result in serious injury and/or death.

SHOOTER. Correct braking

5.

Release mechanical parking brake.

6.

Activate transmission. As soon as machine starts to move, apply service brake pedal. The machine should stop immediately.

3-11

OPERATION

BEFORE OPERATING THE SQUARE SHOOTER@

[LDANGER

Never operate the machine with a faulty backup

alarm. Doing so may result death.

7.

Place transmission control in reverse. The backup alarm should sound. backup alarm repaired immediately. When machine

starts to roll, tion and backup alarm should stop when brake pedal depressed. This action verifies that transmission clutch cutoffis working properly.

APPLY service brakes. The machine

in

serious injury and/or

If

it does not sound, have the

mo-

is

8.

Check rear view mirror. When properly adjusted, the

top

half

of

right rear tire should fill glass.

3-12

OPERATION

NOTES

3-13

OPERATION

OPERATING THE 4-WAY CONTROLLER

Two factors in the perfonnance controller are engine RPM and oil flow.

All SQUARE SHOOTER models will perfonn load chart

capacities at engine idle. Engine rpm may be raised to increase speed

Higher engine rpm of

the optional SQUARE SHOOT( Level Traverse)

function.(Burton Pushed)

of

®

hydraulic function.

is

recommended to enhance perfonnance

of

the 4 way

rl--

I r -

I

I:

n

"1

: I

II'

!

l::--'-L

--

-

-r

0

I

: F I 1

--

___

"1-"

Ii;

'

1_-,

..--'-"

,!

A

E

---=--"".

c

i

8

By moving the 4 way controller gradually to full open, smooth and controlled functions will result.

Quick and sharp movement

jerky

in

and uncontrolled functions.

of

4- way controller will result

3-14

OPERATION

The forks should be tipped back slightly during transportation to ensure stability

it

WARNING

Transporting a load with the boom above horizontal could cause a roll over hazard.

of

load.

The load should be kept as low to the ground as possible without lifting the boom above horizontal.

3-15

OPERATION

TRANSPORTING A LOAD

LLWARNING

Slower speeds should be used whenever transporting a load. Failure to do so can result in damage to load, machine, and bystanders.

Always keep boom retracted as far as load will allow

to ensure greater stability. By using the letters on the

boom side the operator can judge how far the boom

may be extended with that particular load.

3-16

OPERATION

LIFTING A LOAD

Always place load in center frame and completely against the back. By doing

so greater stability

ofthe

fork

load will result.

IMPORTANT Never attempt to use the forks and! or

attachments for prying wedged or frozen loads free.

Damage to load, pallet and/or machine could result.

3-17

OPERATION

PLACING OF A LOAD

[LDANGER

Always apply parking brake before lifting and placing a load. Failure to do so could allow machine to roll

causing a roll over hazard which could result in injury or death.

lor

On

models equipped with front stabilizers, arms should be lowered until weight is supported by arms before placing a load. Front stabilizers are standard on model ( SS - 1048) .

3-18

OPERATION

PLACING A LOAD

& WARNING

Do not sway machine with boom above the horizontal posi-

By

tion. may result in injury or death.

doing so could cause a roll over hazard that

Before placing a load, the frame level should be adjusted at this point. This can be done by the use SWA Y CONTROL located on the dash panel.

Adjust until level gauge indicator ball is located on the

mark.

of

the switch labeled

(0)

3-19

OPERATION

PLACING A LOAD

On models equipped with rear lockup cylinders (SS-l 048 and SS-842) depress and hold service brake pedal throughout entire placement procedure. Cylinders become locked when service brakes are applied.

Gradually move 4-way controller towards position (B) to lift load vertically. Hold until required height has been reached.

rl--

I

I:

n

"1

: 1

1/'

ll--tl_L"!

--

-

r--r

0

I

Ii:

: F 1 1

--

__ . .--./../

1"-"

'

i

--

8

A

E

........

c

3-20

OPERATION

PLACING A LOAD

Gradually to bring Lower load until

move

boom

DOWN

4-way

controller towards position (E)

and

OUT

into final position.

weight

is completely

off

forks.

rl--

I

r--r

I

I:

n

1'1

: I

III

(

l-_LLL',!

--

-

I

: F I 1

--

___

1-"

0

Ii;

I

.--'../

A

E

c

i

B

On

machines equipped with the optional SQUARE

SHOOT

position

NOTE: The button has

SHOOT function.

feature move

(C)

to

4-way

controller toward

bring load into final position.

to

be pushed

to

activate the

SQUARE

3-21

OPERATION

RETRACTING FROM A LOAD

Gradually move 4-way controller towards position (F) to bring the out

ofload.

be lowered.

boom

UP and IN. This will bring the forks

Once forks are clear

ofload

the boom can

E

c

On machines equipped with the optional SQUARE SHOOT function move the 4-way controller towards

position (D) to retract forks from load. Once forks are

clear

ofload

NOTE: The button has to be pushed to activate the SQUARE

SHOOT function.

the boom may be lowered.

LLDANGER

Do not operate machine with the boom above the horizontal position.

3-22

OPERATION

NOTES

3-23

SECTION 4

MAINTENANCE

PROCEDURES

4-1

TABLE

OF

CONTENTS

SECTION 4- MAINTENANCE PROCEDURES:

General Safety Practices

Weekly (Or 50 Hours) Maintenance 4-6

Six Month (Or 1,000 Hours) Maintenance 4-14

Yearly

Hydraulic System Contamination Prevention 4-28

(Or 2,000 Hours) Maintenance 4-27

4-1

4-2

MAINTENANCE PROCEDURES

GENERAL SAFETY PRACTICES

BEFORE SERVICING

Read entire Maintenance Procedure Section.

Familiarize yourself with all safety precautions listed in section

Pay close attention to all safety alert symbols.

Be sure section.

Wear protective equipment.

1.

you

understand the procedures detailed in this

Remove rings and jewelry.

Move machine to a safe level work place.

Lower

boom

and support all raised equipment.

Shut down machine.

Remove key from ignition.

Be careful with fuels and lubricants so as not to spill.

Do

not

fuel tank while engine

so could cause a fire and/or a explosion.

Do not smoke while refueling or working with fuel to avoid a fire and/or an explosion.

IMPORTANT! Always clean up spilled fuel and/or

lubricants to avoid polluting the earth.

is

running or hot. Doing

4-3

MAINTENANCE PROCEDURES

HYDRAULIC SAFETY

LL

WARNING

GENERAL SAFETY PRACTICES

Hot hydraulic oil can cause severe bums. DO NOT work on the hydraulic system

Before ANYONE works on the hydraulic system:

1.

Lower forks to the ground.

2.

Engage parking brake.

3.

Shut down engine.

4. Clean area around reservoir cap.

5.

Loosen reservoir cap.

6.

Remove key from starter switch.

if

oil temperature exceeds

120

o 0

F (49 C).

FLUID UNDER PRESSURE

LLWARNING

Escaping fluid under pressure can penetrate the skin and cause serious personal injury.

Use a piece leaks.

ing lines, be sure to relieve all pressure. Before applying pressure to the system, ensure that all connections are tight. to a damaged line, hose or fitting.

If

injured by escaping fluid, see a doctor at once.

Proper medical treatment must be administered

immediately. A serious infection or reaction can result without proper medical treatment.

of

cardboard or paper to search for

DO NOT use hands! Before disconnect-

DO NOT apply pressure

4-4

MAINTENANCE PROCEDURES

GENERAL SAFETY PRACTICES

WELDING PRECAUTIONS

Lt WARNING

DO

NOT

weld on any structural member. Any unauthorized welding can cause structural failure or possible personal injury. All unauthorized welding or repair procedures will void the warranty.

Before performing any authorized welding, be sure to disconnect positive lead from battery. Properly attach ground cable that

is

being welded. Failure to do so can cause

electrical system damage.

of

welder to frame member

4-5

MAINTENANCE PROCEDURES

WEEKLY (OR 50 HOURS) MAINTENANCE

l.

Perform nance and checks, as listed beginning on page 3-3

2.

Perform "BEFORE OPERATING THE SQUARE

SHOOTER" checks as listed beginning on page 3-8

3.

Remove and inspect air cleaner according to the following procedure:

A Remove and clean cup assembly.

"BEFORE STARTING THE ENGINE" mainte-

®

of

this manual.

of

this manual.

B. Check the condition

Clean or replace as needed. Refer to Engine Manual for more detailed instructions.

C.

Replace cup assembly.

D.

Check air cleaner hose connections between air cleaner

housing and the engine intake manifold for damage or

leaks.

of

the air cleaner element.

4-6

MAINTENANCE PROCEDURES

WEEKLY (OR 50 HOURS) MAINTENANCE

4. The average engine oil change interval hours

of

operation. engine oil and oil filter. Mark the date and engine's hours on the new oil filter. oil change details.

NOTE: Engine manual available from SQUARE

SHOOTER

5.

Check the Hydraulic Pressure Filter element. This filter has a service indicator built into the manifold.

dealer.

If

that interval

See engine manual for

is

250

is

up, change

[LWARNING

Do not operate steering to rear axle (4-wheel or oblique) during this test hazard for the personnel observing the pressure filters

service indicator.

as

tire movement may create a crush

To test the filter element, the steering selector valve must be in the 2-wheel position and there must be a flow through

that this filter serves.

With the engine at about half RPM, operate the steering rapidly back and forth while someone observes the

pressure filter's service indicator.

it.

The steering circuit

is

the largest user

of

oil

4-7

MAINTENANCE PROCEDURES

WEEKLY (OR 50 HOURS) MAINTENANCE

If

the service indicator recommends changing the filter

element follow the procedure listed below:

A. Shut

B. Open the reservoir fill cap to vent the tank's internal

C.

D. Remove the o-ring from the bowl lip and wipe the

E. Install a new 10 micron paper element into the head

F.

G. Screw the bowl back into the head assembly

H. Tighten the bowl to 30

off

the engine and remove the key from the switch.

pressure

Using a 1-3/8 inch wrench, unscrew the bowl from the head assembly. Remove the paper element from the head assembly

bowl clean.

assembly

Install a new the bowl.

the pressure filter.

(5

to 10 PSI).

by

pulling down on it.

of

the pressure filter.

a-ring

into the groove in the lip

ft.

lbs.

of

torque and wipe dry.

of

4-8

MAINTENANCE PROCEDURES

WEEKLY (OR 50 HOURS) MAINTENANCE

6.

Check the hydraulic return filter element. The filter has a service indicator built into the body. It is mounted on the forward surface reservoir, left side, near the top and has an aluminum body with a white spin on element.

The at rest reading should read between 0 and 7 PSI as the machine has a pressurized reservoir.

To test the hydraulic return filter the hydraulic fluid

must be at least 400degrees F and the engine must be running. If

these conditions exist, have one person operate the

boom up at full engine RPM to create flow through

the filter. While this

observe the filter pressure gauge.

is

being done have another person

of

the hydraulic oil

The gauge should read less than the flow test, on element should be changed according to the following procedures.

A. Lower oil level in reservoir by extending the boom fully

at ground level and tilting fork frame fully down.

B. Sway the machine fully to the right, shut

key from start switch. Do not restart the engine until filter element change

C.

Open hydraulic oil reservoir fill cap to vent pressure. Steps (A) (B) and (C) are performed to prevent oil from being dumped on personnel when this change is performed.

D.Remove the spin-on element Item 2 from the head

assembly Item

E. Remove rubber seal ring from head assembly

F.

Install new rubber seal ring

G. Wipe a film

install it on return filter head assembly( Item 1). Hand tighten spin on element (Item 2) and wipe it dry.

if

gauge reads more than

is

complete.

10fthe

return filter.

of

oil around outer lip

15

PSI (

bypass)

15

PSI the spin

off

in

the head assembly

of

new spin-on element and

during

engine and remove

of

return filter.

of

return filter.

4

2

H.

Close hydraulic oil reservoir fill cap.

4-9

MAINTENANCE PROCEDURES

WEEKLY (OR 50 HOURS) MAINTENANCE

7.

Perform weekly greasing on components using a premium multi purpose

on

grease as listed below. Refer to lube chart component location. Clean all grease fittings before greasing.

pages 4-12&

13

for

A. Head and base ends

B. Slip yoke

C.

Slip yoke

D. Universal joints

parking brake disc (3).

E. Axle trunnion (steering) bearings, front and rear (8).

F. Both ends

G.

Tie rod ends

H. Brake pedal pivot (1).

I.

Accelerator pedal pivot (3).

J.

Upper slide on lift copy assembly (2) Optional on all models except

SS-624.

K. Lower slide on lift copy assembly. (1) Optional on all models except

SS-624.

on

rear axle (1).

of

sway cylinders (4).

front axle (1).

on

both driveshafts, with the exception

all four steering cylinders (8).

on

both axles (4).

of

joint by the

L. The boom's rear pivot (2).

M. Two chain sheaves on front

roller shaft (2) (NOTE: SS-836 only.)

N. Extend the

four grease fittings on the side plates. section boom, therefore only the large boom will have these grease fittings.) on

the sides tubes where rub occurs. Models have eight grease fittings. The SS-624 will have four.

boom

fully. The large and middle

Put four pumps

of

the

intemalload

of

middle boom tube. Fittings in the end

boom

tubes each have

(NOTE: The SS-624

of

grease into each fitting. This smears grease

rollers and lubes inside

SS-l

048, SS-842, SS-836 & SS-636

of

the boom

4-10

is

a two-

of

MAINTENANCE PROCEDURES

WEEKLY (OR 50 HOURS) MAINTENANCE

ffiDANGER

®

SQUARE SHOOTER FORKLIFTS ARE BALLASTED WITH WEIGHTED TIRES. LOSS OF BALLAST A ROLL OVER HAZARD RESULTING IN DAMAGE,

8. Check tires for chloride and inflation pressure.

CAN EFFECT MACHINE STABILITY AND CAN CAUSE

INmRY

OR DEATH

A. With valve stem at its highest point, push deflator point

a full second. There should be a solid stream If

air is present,tire solution to a level submerged solution

NOTE: The SS-624 is the only SQUARE SHOOTER tractor without weighted tires.

Use only a corrosion

B.

to

70 PSI.

in chloride solution, it will rust causing early failure. Proper chloride

is

150 Ibs.

is

under-filled with chloride solution. Replace the lost chloride

of

one inch above the steel wheel. Also

of

calcium chloride to 50 gallons

proof

tire gauge to check tire pressure. Tires should be inflated

of

chloride solution and no air.

of

valve core for about

if

steel wheel

of

water.

is

not kept

4-11

MAINTENANCE PROCEDURES

LUBE CHARTS

SS-624

SS-636

\ I

~

1 1

GR(J\~C

BOOM

n.lU.v

BOTt'

510

ES

8CENf::F.C

W n I

1 1

2:

(BD1IND

2

COVER)

SS-836

111

~~

1 1 1 I 1

4-12

~

1 I

~

1 1 1 1

11

SS-842

MAINTENANCE PROCEDURES

LUBE CHARTS

I

"'UllE!) ~ ..

POIlERlFAIW!lIIiLY

rtf

I

SS-1048

~

, J

11

2.

(miND

OJVDO

.~~~

I,

"1

, 1 1 1

4-13

MAINTENANCE PROCEDURES

SIX

MONTH (OR 1,000 HOURS) MAINTENANCE

1.

Perform "BEFORE STARTING THE ENGINE" maintenance and checks, as listed beginning

of

on page 3-3

this manual.

2. Perform on page 3-8

3. Perform

on page 4-5

4. Change engine fuel filter according to John

SQUARE SHOOTER or John Deere dealer.

5.

Change hydraulic oil reservoir breather element. (A) This spin-on type filter is located on the top surface of

"BEFORE OPERATING THE SQUARE SHOOTER" checks, as listed beginning

of

this manual.

"ONCE A WEEK (OR 50 HOURS) MAINTENANCE" procedures, as listed beginning

of

this manual.

Deer~

the oil reservoir. HAND TIGHTEN ONL

Yl

®

specifications. For more information contact your local

1

4-14

A

MAINTENANCE PROCEDURES

SIX MONTH (OR 1,000 HOURS) MAINTENANCE

6.

Change transmission oil filter. To change transmission oil

filter use the following procedure:

A.

Using a that secure the access cover.

B. Wipe the filter clean. Rotate counterclockwise

and remove. Clean sealing face

112

inch wrench, remove two 5/16 inch bolts

of

filter mount,

as

needed.

C. Smear a drop

Install filter hand tight.

D. Before replacing access cover, run engine long enough to

check transmission oil level.

filter. Add oil as needed. Use Amoco 1000, or equivalent.

E.

Replace access cover and two 5/16" bolts. Secure bolts.

of

oil around rubber seal ring

Oil level dipstick

of

new filter.

is

next to oil

4-15

MAINTENANCE PROCEDURES

SIX MONTH (OR 1,000 HOURS) MAINTENANCE

7.

Change oil in all four (4) planetary brakepack ends. This fluid gradually becomes contaminated from the wearing action these axle ends with an SAE EP rated at GL-5. Refer to SQUARE SHOOTER

dealer for recommended axle end oil. Fill to the 1/8"

NPT plug at center

of

the brakes. Refill

90 weight oil that

of

planetary end.

is®

8.

Check lube level in center differentials To check lube level use the following procedures:

A.

Remove the plug. Fluid level should be at the lower

of

the plug hole.

lip

B. Refill with a quality SAE 90 weight fluid.

C.

Replace the plug.

of

both axles.

4-16

MAINTENANCE PROCEDURES

SIX MONTH (OR 1,000 HOURS) MAINTENANCE

9.

Re-torque bearings in boom pivot. See SERVICE NOTES for "The Boom Pivot's Two Adjustments".

NOTE: This step

10.

Check boom extension and retraction chains for slack. For particular Model requirements refer to the following pages.

Model SS-1048 see page 4-19

Model SS-842 see page

Model SS-836 see page 4-21

Model SS-636 see page 4-22

is

applicable to Model SS-836 only.

4-20

NOTE: Model SS-624 does not use extension and

retraction chains.

4-17

MAINTENANCE PROCEDURES

SIX MONTH (OR 1,000

11.

Visually check SQUARE SHOOT drive

chain for proper tension. Follow the procedure outlined in SERVICE NOTES, "Proper Tensioning SQUARE SHOOT Drive Chain".

SQUARE

SHOOTEt'

of

the

HOURS)

MAINTENANCE

Check and adjust engine valve clearance. For more information contact your local SQUARE SHOOTER or John Deere dealer.

®

4-18

MAINTENANCE PROCEDURES

SIX MONTH (OR 1,000 HOURS) MAINTENANCE

ADJUSTING EXTENSION-RETRACTION CHAINS, SS-1048

CHECK POINTS: Proper adjustment can be checked with a tape measure. Extend boom fully, then retract about one

inch.

On either side

center.

surface

Place one end

of

boom directly above estimated center.

of

the booms middle section estimate

of

tape measure on the top

TOLERANCE: Measurement from top surface boom to lowest part no less than 2- 3/8 inches.

TO ADIDST: tighten chain anchor (A), which the large boom tube

A. Tighten an adjustable wrench across the flat part

the chain just ahead

B.

With a 1-7/16 inch wrench tighten the one inch nut to collapse the springs. Continue to tighten until chain is

in tolerance.

C.

With a feeler gauge check the gap between the spring coils should be no less than .030. Coils should never be

collapsed completely.

NOTE. There are two chains on the SS-1048. Both chains should have the same measurement.

of

extension chain should be

If

the measurement

as

follows:

of

is

less than 2- 3/8 inches,

is

located on the top, front

the chain anchor.

of

4-19

A

MAINTENANCE PROCEDURES

SIX MONTH ( OR 1,000

ADJUSTING EXTENSION-RETRACTION CHAINS, SS-842

CHECK POINTS: Proper adjustment can be checked with a tape measure. Extend boom fully, then retract about one inch.

section estimate center. measure on top surface

estimated center.

TOLERANCE: Measurement from top surface

boom to lowest part

less than 2-3/8 inches.

On either side

Place one end of

boom directly above

of

extension chain should be no

of

middle

tape

of

HOURS)

MAINTENANCE

TO ADJUST:

tighten chain anchor (A), which

of

the large boom tube

A. Tighten an adjustable wrench across the flat part

the chain just ahead

B.

With a

to collapse the springs. Continue to tighten until chain

is

in tolerance.

C.

With a feeler gauge check the gap between the spring should be no less than be collapsed completely.

If

the measurement

as

follows:

of

1-7116

inch wrench tighten the one inch nut

.030

is

less than 2-3/8 inches,

is

located on the top, front

the chain anchor.

..

Coils should never

of

A

4-20

MAINTENANCE PROCEDURES

SIX MONTH ( OR 1,000

ADJUSTING EXTENSION-RETRACTION CHAINS, SS-836

CHECK POINTS: Proper adjustment can tape measure. Extend boom fully, then retract about one inch.

On

either side Place one boom directly below estimated center.

TOLERANCE: Distance from bottom surface to lowest part than 4 inches.

FIRST ADJUSTMENT: go to the underside front

extension chain anchors.

A. Tighten

chain.

end

an

of

middle section estimate center.

of

tape measure

of

both

extension chains should be no more

adjustable wrench across the flat part

on

If

the tolerance

of

the large boom tube to the two

be

checked with a

bottom surface

of

is

more than 4 inches,

of

boom

of

the

HOURS)

MAINTENANCE

B. Using a 1-7/16 inch wrench tighten the nut until the 4 inch

tolerance is achieved. Repeat the procedure on the other chain.

NOTE: Both chains of

the large section,

SECOND ADJUSTMENT: 4 inches, you will have to adjust thecompression spring. This spring is located on the front top area tube. The gap between the majority be

no less than .030. Measure gap with a feeler gauge. To collapse the coils down to on both nuts on the adjuster shaft and tighten until coil gap is correct.

on

the SS-836 are located on the bottom

and

should have the same measurement.

If

the measurement is still more than

of

the large boom

of

the spring coils should

.030 gap, place a 1-7/16 inch wrench

4-21

MAINTENANCE PROCEDURES

SIX MONTH (OR 1,000

ADJUSTING OF THE EXTENSION-RETRACTION CHAINS, SS-636

CHECK POINTS: Proper adjustment can be checked

with a tape measure. Extend boom fully, then retract

about one inch. estimate the center. Place one end

top surface

center.

TOLERANCE: Measurement from top surface boom to lowest part no less than 2- 3/8 inches.

On either side

of

boom directly above estimated

of

middle section

of

tape measure on

extension chain should be

of

HOURS)

MAINTENANCE

TO

ADJUST:

tighten chain anchor (A), which

of

the large boom tube as follows:

A. Tighten an adjustable wrench across the flat part

the chain just ahead

B. With a

to collapse the springs. Continue to tighten until chain is

in tolerance.

C.

With a feeler gauge check the gap between the spring should be no less than collapsed completely.

If

the measurement

of

1-7116

inch wrench tighten the one inch nut

.030. Coils should never be

is

less than 2-3/8 inches,

is

located on the top, front

the chain anchor.

of

A

4-22

MAINTENANCE PROCEDURES

SIX MONTH (or 1,000 HOURS) MAINTENANCE

ADJUSTMENT OF BOOM PIVOT (SS-836

LOCATION: Top central area left and right sides.

SEQUENCE: Two adjustments are required on the boom pivot: preload and

PRELOAD: Place fork frame about 4 feet in front

and lower to the ground. This relieves the load on boom

pivot.

A.

On each side inch capscrews and four

1/2

inch.

boom

centering. Bearing preload must be done first.

of

machine, back out eight

of

the frame's rear towers, both

of

1/2

NF x 2

1/2

NF x 1 inch set-screws about

machine

ONLy)

B. The 1-112

end. While holding one nut, tighten other nut to 500

C. Raise and lower boom once to seat bearings. Again,

tighten the

CENTERING: A. Tighten four set-screws on the side frame in which the boom needs to be moved ,to approximately 10

ft.

B. Tighten all eight

inch diameter tie bolt has a nut on each

1-

112

inch tie bolt nuts to 500 ft.lbs.

lbs.

112

NF

x 2 inch capscrews to

65

ft.

of

lbs.

the

lbs.

4-23

MAINTENANCE PROCEDURES

SIX MONTH (OR 1,000 HOURS) MAINTENANCE

PROPER TENSION OF OPTIONAL SQUARE SHOOT DRIVE CHAIN,

MODEL SS-836

PROBLEM: will affect the onset speed after button may double up and cause drive chain failure.

TO CHECK: Collapse boom, then raise boom fully. Stop engine and move to rear tension visually. Square Shoot drive chain exits the boom tube, over a sprocket. This sprocket elevates the drive chain about

inch above top surface

TOLERANCE: The distance between where chain exits sprocket and the start

in the boom top tightened enough so it does not touch boom between the sprocket and the start

TOOLS: 9/16 inch wrench,

extension, 15/16 inch wrench, small grinder, small hammer, small punch and safety glasses. Remove the rear boom

cover by removing the two 3/8 inch bolts. Adjust tension

using the following procedure:

If

Square Shoot drive chain becomes loose it

of

Square Shoot function

is

pushed.

If

chain becomes extremely loose it

of

machine. Check drive chain

On top rear

of

is

14

inches. The drive chain should be

of

the large boom tube, the

of

large boom tube.

the two narrow cutout holes

the two narrow cutout holes.

15116

crowsfoot, ratchet,

118

12

inch

TO ADJUST: is

located under and forward

end

is

pinned to middle boom and rearward end to drive chain.

The boom anchor end has a stiff coil spring inside

that

is

attached to a 5/8 NF diameter threaded rod.

A 5/8 NF nut

thread rearward

nut. A second 5/8 NF nut threaded rod. the 5/8 NF threaded rod and the other end pins onto

drive chain.

B.

Use the 15/16 inch crowsfoot, ratchet to crack loose the 5/8 NF jam nut. The jam one closest to you.

C.

To tighten or adjust nut, rotate the forward nut counter-

clockwise until there

1 inch gap. The gap spring in the chain anchor. Tighten the jam nut and replace rear boom cover. proceed to step

A.

The three-piece chain adjuster assembly

of

sprocket. The forward

is

brazed onto rod with 2 -5/8 inches

of

the nut. This nut

One end

of

is

D.

is

used

drive chain anchor threads onto

a minimum

the amount you have collapsed the

is

the tension adjust

as

a jam nut on the

12

inch extension and

114

inch to a maximum

If

chain

is

still loose,

of

is

the

4-24

MAINTENANCE PROCEDURES

SIX MONTH (OR 1,000 HOURS) MAINTENANCE

PROPER TENSIONING OF OPTIONAL SQUARE SHOOT DRIVE CHAIN,

SS-836

If

boom adjuster ran out minimum gap was achieved a link must be removed from drive chain.

Remove drive chain anchor from boom anchor. Leave chain anchor on chain and let chain hang over sprocket.

LLCAUTION

Always wear safety glasses to protect your eyes from debris from grinding.

of

travel before the

114

inch

D.

Wearing safety glasses, pull down on chain anchor to tighten chain. first chain side link up from chain anchor.

E.

Use a small hammer and punch to remove link from chain.

F.

Remove master link from chain anchor. Discard removed chain link and reinstall chain anchor to the shortened drive chain with master link. See remove a link procedure on next page.

G.

Install chain anchor to boom anchor and adjust chain tension page. Re-install rear boom cover.

Use grinder to grind

as

detailed in step (C) on previous

off

two rivet heads on

4-25

MAINTENANCE PROCEDURES

SIX MONTH (OR 1,000) HOUR MAINTENANCE

PROPER TENSIONING OF OPTIONAL SQUARE SHOOT DRIVE CHAIN

MODELS SS-1048, SS-842 AND SS-636

If

Square Shoot drive chain becomes loose it will affect onset speed pushed. up and cause drive chain failure.

TO CHECK: Collapse boom, then raise boom fully. Stop engine and move to rear tension visually. On top rear

Shoot drive chain exits continues forward to another sprocket where it enters large

boom.

TOLERANCE: The drive chain should never be slack enough to touch top

of

Square Shoot feature after button

If

chain becomes extremely loose it may double

of

machine. Check drive chain

of

large boom tube, the Square

boom

tube over a sprocket and

of

large boom

is

TO ADIDST: Place boom in horizontal position. Loosen four bolts holding idler sprocket mount to top front boom. Insert a small pinch bar into hole mount and is

still inadequate adjustment available, anchor can be turned around. A link can be removed much chain. To do so use the following procedure.

Always wear safety glasses to protect your eyes from debris from grinding.

TO REMOVE A LINK: A. Loosen the four bolts holding

idler sprocket mount to boom.

B. Remove rear boom cover.

C.

Just inside the boom notice where the drive chain attached link. Disconnect link and pull chain out

D. Wearing safety glasses, grip last link in chain with a

pair rivets ahead

pry

mount while tightening four bolts.

[LCAUTION

to

rear

of

middle boom by means

of

locking pliers. Grind heads

of

last link.

just

if

there

of

off

the first two

to rear

is

still to

of

a master

large

of

large

of

Ifthere

is

boom.

E. With a small punch and hammer, knock out the two link

pins that were just ground off. Discard removed link.

F.

Reattach drive chain to rear

master link. Re-install rear boom cover.

G.

Adjust chain as outlined above, under TO ADIDST.

of

middle boom with

4-26

MAINTENANCE PROCEDURES

YEARLY (OR 2,000 HOURS) MAINTENANCE

1.

Perform "BEFORE STARTING THE ENGINE" maintenance and checks as listed beginning page 3-3

of

this manual.

on

2. Perform "BEFORE OPERATING THE SQUARE SHOOTER" checks as listed beginning page 3-8

3.

Perform" page 4-5

4.

Perform "SIX page 4-12

5. Drain, flush SHOOTER

of

this manual.

ONCE A WEEK

of

this manual.

MONTH

of

this manual.

and

refill the engine coolant system. For more information contact

or

John Deere®dealer.

(OR

50 HOURS) MAINTENANCE" procedures as listed beginning

(OR

1,000 HOURS) MAINTENANCE" procedures as listed beginning

®

your

local SQUARE

on

4-27

MAINTENANCE PROCEDURES

HYDRAULIC SYSTEM CONTAMINATION

A hydraulic system will fail hydraulic system clean.

Clearances in hydraulic components may be extremely close. Many systems have clearances less than parts and hone surfaces to greater clearances. Increased clearance has the direct effect efficiency also generates system damaging heat.

THE

Contaminant particle size millionth

Contamination is very often the cause necessary to follow proper maintenance procedures to keep the hydraulic system clean.

The figure below is a comparison

0.0001 inch. Problems arise when abrasive particles enter the space between moving

of

pumps, motors and cylinders. The damage that occurs

MICRON

of

a meter (0.000039 in.), for example, 25 microns is approximately 0.001 inch.

INCHES MICRONS

.005

130

120

if

there

is

measured

is

contamination in the system.

by

micron ratings. A micron is a unit

of

hydraulic system failure. That

of

various known sizes

AL

WAYS keep the

not

of

different particles.

of

decreasing

only wastes horsepower, it

of

length to one-

is

why it

is

absolutely

110

.004 100

-

TableSalt

90

.003

.002

.001

~--

80

70

60

50

40

30

20

10

......

Human Hair

Pollen

Fog

Vlslbiiliy

White

-------------

- Bacteria

limit

Blood

Red

Cells

Blood

200

Mesh Screen

Cells

Talcum

IMPORTANT! USE factory approved filters only! KEEP

hydraulic

system

CLEAN

for long life.

4-28

MAINTENANCE PROCEDURES

NOTES

4-29

SECTION 5

MATERIAL

SAFETY DATA SHEETS

5-1

TABLE

SECTION 5- MATERIAL SAFETY DATA SHEETS

OF

CONTENTS

5-2

MATERIAL SAFETY DATA SHEETS

The Federal Occupational, Safety and Health Administration (OSHA) Standard 29 ctr 1910.1200, and in some cases state and local Right-To-Know laws, may require specific MSDS be available to

on

employees prior to operating this equipment. This may include information in the equipment such as antifreeze, brake fluid, battery acid and hydraulic fluid.

substances contained

TEREX HANDLERS will provide, at no cost, Material

the

SQUARE SHOOTER@brandproduct line. Simply request them from your local SQUARE

SHOOTER

TEREX HANDLERS P.O. Box 248 Baraga, MI http://www.sqshooter.com E-mail: bpi@up.net

To ensure a prompt response, please be sure to include your return address and zip code, along with the machine model and serial number.

dealer or contact us at:

49908-0248

Safety Data Sheets which are applicable to

5-3

MATERIAL SAFETY

DATA

SHEETS

The following warning is required on all

you are operating a SQUARE SHOOTER@in the State

warning label, please contact us for a replacement at no charge.

TEREX HANDLERS P.O. Box 248 Baraga, MI 49908-0248

http://www.sqshooter.com

E-mail: bpi@up.net

Diesel engine exhaust and some constituents are known to the State of defects, and other reproductive harm.

off

road equipment operating

of

California and do not see the approved

CALIFORNIA

Proposition

California to cause cancer, birth

65

Warning

in

the State

Our address is:

of

its

of

California.

If

5-4

Genie Square Shooters Series Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual