JLG sky trak mmv Service Manual

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Model MMV

TM 10794A-24/2

OM0651

SERVICE MANUAL

8990440

PCN 500 107941 00

Printed in U.S.A. 12/04

EFFECTIVITY PAGE

December 17, 2004 - B - Replaced all branding with JLG.

8990440 MMV i

EFFECTIVITY PAGE

MMV 8990440-ii

SECTION CONTENTS

Section Subject Page

Section 1

Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.2 Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.4 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.5 Accident Prevention Tag Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.6 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.7 Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.8 Hazard/Emergency Information Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

Section 2

General Information, Specifications and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2.1 MMV Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

2.4 Metric Conversion Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

2.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

2.6 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

2.7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.9 Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.11 Pressure Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.12 After Service Startup and Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.13 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.14 Emergency Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.77

2.15 Parking Brake/Transmission De-Clutch Test Procedures . . . . . . . . . . . . . . . . . . . . . . . 2.81

Section 3

Cab, Covers and Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

3.1 Operator’s Cab and Covers Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

3.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

3.3 Operator’s Seat and Seat Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24

3.4 Cab Heater/Air Conditioning Blower Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26

3.5 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30

3.6 Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.43

3.7 Access Panels, Covers and Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.44

Section 4

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

4.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

4.2 Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

4.3 Boom Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

4.4 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

4.5 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46

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Section Subject Page

Section 5

Axles, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

5.1 Axle and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

5.2 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17

Section 6

Transfer Case and Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

6.1 Transfer Case and Drive Shaft Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . 6.2

6.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.3 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3

6.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

6.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14

Section 7

Transmission: ZF 4 WG-98 TS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

7.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

7.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3

7.3 Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3

7.4 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3

7.5 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.6 Transmission Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.7 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

7.8 Towing a Disabled Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18

7.9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19

Section 8

Engine: Cummins 4BTA 3.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

8.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

8.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

8.5 Standard Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

8.6 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7

8.7 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18

8.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.18

8.9 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25

8.10 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26

8.11 Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.45

8.12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.46

Section 9

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

9.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

9.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

9.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

9.4 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.5

9.5 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

9.6 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

9.7 Hydraulic System Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10

9.8 Hydraulic Circuits and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13

9.9 Steer Indexing Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.85

9.10 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.86

Model MMV Rev. 12/17

Section Subject Page

9.11 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.87

9.12 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.98

9.13 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.136

9.14 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.142

Section 10

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

10.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

10.2 Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

10.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

10.4 Effective Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

10.5 Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

10.6 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

10.7 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

10.8 Transmission Gear Selection Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.72

10.9 Dash Panel Warning Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.80

10.10 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.88

10.11 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.91

10.12 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.108

10.13 Switches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.134

Section 11

Stabil-TRAK™ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

11.1 Stabil-TRAK™ System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2

11.2 Stabil-TRAK™ Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3

11.3 Stabil-TRAK™ Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4

11.4 Stabil-TRAK™ Circuit Operation and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 11.6

11.5 Stabil-TRAK™ System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.28

Section 12

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1

Accident Prevention Tags

Model MMV Rev. 12/17

iii

Section Subject Page

Model MMV Rev. 12/17

Section 1

Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.2 Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.4 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.4.1 Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.4.2 Hazard Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.5 Accident Prevention Tag Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.7 Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.8 Hazard/Emergency Information Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

Model MMV Rev. 12/04

1.1

Safety Practices

1.1 INTRODUCTION

JLG (hereafter, JLG) products meet all applicable indus-

try safety standards. JLG actively promotes safe practices in the use and maintenance of its products through training programs, instructional manuals and the pro-active efforts of all employees involved in engineering, design, manufacture, marketing and service.

This manual is designed to provide service technicians with complete information on the maintenance and repair of the Sky Trak MMV Telescopic Material Handler.

Particular effort has been made to produce a manual to serve as a reference handbook for the experienced service technician, but also provide essential step-by-step procedures for the professional development of the less experienced person. Remember, even the best manual in the world is no substitute for an appropriate education, skill development that comes through experience alone, safety, wise and judicious discernment, and ultimately, proper performance of service procedures.

This service manual provides general directions for accomplishing service and repair procedures with tested, effective techniques. Following the procedures in this manual will help assure safety and equipment reliability.

Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws. Prior to performing any maintenance on the vehicle, consider all factors, circumstances and conditions which can have an effect upon the safety of personnel and equipment, and take appropriate action to ensure the safety of all involved.

These instructions cannot cover all details or variations in the equipment, procedures or processes described, nor provide directions for meeting every possible contingency during operation, maintenance or testing. When additional information is desired to satisfy a situation not covered sufficiently, consult the local JLG Authorized Service Center (ASC) or the JLG Service Department at 1-877554-5438 or 1-717-485-5161.

Many factors contribute to unsafe conditions; carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. Although equipment damage can usually be repaired in a brief period of time, death and irreparable injury are permanent. For optimal safety, encourage everyone to think, and to act, safely.

Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the vehicle.

Provisions for supplementary information are made by JLG in the form of Service Bulletins, Service Campaigns, Service Training Schools, the JLG web site, other literature, and through updates to the manual itself. Comments and suggestions for improvement are welcome and encouraged.

All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication approval. JLG re- serves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1.2 OWNERS/OPERATORS MANUAL

The vehicle must be driven and operated as a consequence of, or when performing, service, maintenance and test procedures. The service technician must, therefore, thoroughly read, understand and follow the Sky Trak MMV Telescopic Material Handler Owners/Operators Manual.

An Owners/Operators and EMI Safety Manuals are supplied with each vehicle and must be kept in the pocket (1) located in the lower door in the cab.

In the event that the Owners/Operators or Safety Manuals are missing, consult the local JLG Authorized Service Center (ASC) or the JLG Service Department before proceeding.

1.2

Model MMV Rev. 12/04

MM2240

1.3 TRAINING MECHANICS AS OPERATORS

Because it is necessary to move the vehicle to service or maintain the vehicle, it is necessary that all mechanics are OSHA trained and certified as operators. A mechanic trained in the proper operation of the vehicle can better determine whether all the functions are operating correctly.

Safety Practices

1.4 SAFETY INFORMATION

The following information provides general safety instructions, including examples of hazard statements with signal words, notification of hazards, methods to help avoid hazards and the consequences of failing to follow the safety information. To avoid possible death or injury, carefully read and follow all safety messages. Fully understand the potential causes of death or injury.

In the event of an accident, know where to obtain medical assistance, use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help ensure personal safety.

The information in this manual does not replace any other safety rules or proper judgment. Governmental authorities and employers also have their own sets of rules, codes, regulations and laws. Before starting work at a worksite, check with the supervisor or safety coordinator and ask about the safety policy. Learn the safety requirements in effect before operating, maintaining, servicing or testing the vehicle. Safety depends on following safety requirements.

1.4.1 Safety Alert Symbol

The exclamation mark within a triangle is the Safety Alert Symbol.

At the time of original purchase, the purchaser of this vehicle was instructed by the seller on its proper use. When this vehicle is to be serviced or maintained by someone other than the purchaser, make certain that the mechanic is trained, in accordance with the OSHA regulations listed in the NOTICE below, and reads and understands the Sky Trak MMV Telescopic Material Handler Owners/Operators Manual before

operating or

maintaining the vehicle.

NOTICE: Under OSHA rules, it is the responsibility of the employer to provide operator training. Successful completion and certification of Safety Training for Rough Terrain Forklifts is required. Operator Training Kits are available by calling Ken Cook Company at (414) 466-6060. An order form for these kits is available through our website, http://www.jlg.com.

In addition, make sure that the mechanic has completed a walk-around inspection of the vehicle, is familiar with all decals and/or decal plates on the vehicle, and has demonstrated the correct use of all controls.

Model MMV Rev. 12/04

OP0330

This symbol means “Attention! Become Alert! Your Safety Is Involved!” The symbol is used to attract attention to safety hazards found on the vehicle safety decals and/or decal plates throughout this manual.

1.3

Safety Practices

1.4.2 Hazard Statements

Signal words and messages are used in conjunction with the safety alert symbol to create hazard statements. These hazard statements convey important information about safety.

Four types of hazard statements are used in this manual. Each statement indicates the existence and degree of relative risk of the hazard described within the statement that follows the signal word.

Explanations of the types of hazard statements are as follows:

DANGER:

The signal word “DANGER” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING:

The signal word “WARNING” indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION:

1.5 ACCIDENT PREVENTION TAG U SAGE

MC0690

Before beginning any maintenance or service, place an Accident Prevention Tag (1) on both the ignition switch (2) and steering wheel (3), stating that the vehicle should not be operated. Actual Accident Prevention Tags, that can be punched out and used, are included as the last page in this manual. Retain these Accident Prevention Tags for reuse at a later date.

The signal word “CAUTION” indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION:

The signal word “CAUTION,” used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, could result in property damage.

For safe maintenance of the vehicle, read, understand and follow all DANGER, WARNING and CAUTION information.

1.4

DANGER

OM1510

Model MMV Rev. 12/04

Safety Practices

1.6 SAFETY INSTRUCTIONS

Following are general safety statements to consider

before

Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the hazard occurs.

For all safety messages, carefully read, understand and follow the instructions

1.6.1 Personal Hazards

HAIR and CLOTHING: DO NOT wear loose clothing or jewelry. Tie up or restrain hair. Wear the correct safety equipment for the job (including but not limited to: hard hat; safety shoes; safety glasses, goggles, or face shield; heavy gloves; hearing protection; reflective clothing; wetweather gear; respirator or filter mask).

E tection when chiseling, grinding, sanding, welding, painting, repairing hydraulic systems, or checking, testing or charging the battery.

B tion when grinding or painting.

H tion in a high-noise area.

F inforced toe caps and slip-resistant soles.

L least one assistant or a suitable sling and hoist.

performing maintenance procedures on a vehicle.

before

YE PROTECTION: Always wear appropriate eye pro-

REATHING PROTECTION: Wear respiratory protec-

EARING PROTECTION: Always wear hearing protec-

OOT PROTECTION: Wear protective footwear with re-

IFTING: NEVER lift a heavy object without the help of at

proceeding.

1.6.2 Equipment Hazards

OWNERS/OPERATORS MANUAL: Before operating the vehicle, carefully read, understand and follow the Owners/Operators Manual.

PERATIONAL PROTECTION: Before operating the vehicle or returning it for operational use, check that the operator’s protective structure is intact, undamaged, unmodified and secure.

IFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working condition and properly attached.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist or jack to support raised equipment. A hoist or jack failure can allow the equipment to fall or tip.

Always support equipment with proper capacity blocks or stands that are properly rated for the load.

OMPRESSED AIR: Before and during the use of compressed air, wear eye protection and advise other personnel in the work area that compressed air is about to be used.

AND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.

Model MMV Rev. 12/04

1.5

Safety Practices

1.6.3 General Hazards

SOLVENTS: Only use approved solvents, and solvents that are known to be safe for use.

OUSEKEEPING: Keep the work area and operator’s

H cab clean and remove all hazards (debris, oil, tools, etc.).

IRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor. Know the location of a first-aid kit, and know how to use it.

LEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service.

When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the vehicle to capture fluid run-off.

1.6.4 Operational Hazards

OPERATIONAL CONSIDERATIONS: Before operating the vehicle, carefully read, understand and follow the Owners/Operators Manual.

NGINE: Stop the engine before performing any service.

ANGEROUS START: Place Accident Prevention Tags

D on both the ignition switch and steering wheel before attempting to perform any service or maintenance. Disconnect battery leads. Place a warning sign on vehicles that are dangerous to start, if leaving the vehicle unattended.

ENTILATION: Avoid prolonged engine operation in en-

closed areas without adequate ventilation.

ADIATOR CAP: Always wear steam-resistant, heatprotective gloves when opening the radiator cap. Cover cap with a clean, thick cloth and turn slowly to the first stop to relieve pressure.

SOFT SURFACES AND SLOPES vehicle that is parked on a soft surface or slope (inclined ground or hill). The vehicle must be on a hard, level surface with the wheels blocked when performing any service. Obtain assistance, block all wheels, and add supports if necessary before beginning any work.

UPPORTS AND STRAPS: Install safe, stable supports, slings or straps, beneath or around a component or structural member before beginning any work.

: NEVER work on a

LUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fuel leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, causing infection, gangrene, and other serious personal injury.

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly, and tightened to the proper torque. Capture fluid in an appropriate container and dispose of it in accordance with prevailing environmental regulations.

RESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedures to achieve the desired results.

EAVING VEHICLE: Lower the attachment to the ground before leaving the vehicle.

IRE PRESSURE: Always keep tires inflated to the proper pressure to help prevent dangerous travel and loadhandling situations. DO NOT over-inflate tires.

1.7 EMERGENCY EXIT REAR WINDOW

The rear window in the enclosed cab can be used as an emergency exit by removing the latch pins (1) located on the two window latches (2). Once the latch pins have been removed, the window (3) can be swung open.

1 0 9

7 9 1

OT08902

1.6

Model MMV Rev. 12/04

Safety Practices

1.8 HAZARD/EMERGENCY INFORMATION SIGNS

Locations of vehicle hazard and other emergency information signs are shown below. As part of routine maintenance, check that ALL hazard and emergency information signs on the vehicle are present and readable. Keep all signs clean.

CONTACTING ELECTRIC POWER LINES can result in electrocution.

WARNING

VEHICLE ROLLAWAY can cause death or serious injury.

WARNING

DANGER

ALWAYS engage parking brake before dismounting.

NEVER operate vehicle within 10 feet (3m) of electric power lines.

AVOID CRUSHING if vehicle tips. Jumping can result in death or serious injury.

DANGER

 DO NOT JUMP.  Brace yourself.  Stay in cab.  Keep seat belt on.

VEHICLE TIPOVER can result in death or serious injury.

DANGER

DO NOT raise

DO NOT

boom while

travel

on a slope

with the

unless load

boom

is level.

raised.

SAFETY INSTRUCTIONS

1. Read operators manual before operating.

2. Fasten seat belt.

MAINTAIN proper tire pressure at all times.

3. Allow no riders.

4. Use an approved work platform to lift or lower personnel.

If a replacement sign is needed, refer to the Owners/Operators Manual and parts catalog for the latest parts numbers and ordering information. Or, contact JLG Inc. directly at:

Domestic: 1-877-554-5438

International: 1-717-485-5161

MOVING PARTS can cut.

Keep clear of fan and belts while engine is running.

MOVING PARTS can entangle.

4109791

Allow no riders.

4. No Riders WARNING

5. Vehicle Rollaway WARNING

6. Electrocution DANGER

7. Load Chart Booklet

8. Tipover DANGER - Operating

9. Do Not Jump DANGER

OT05602

10. Safety Instructions

11. Moving Parts WARNING

12. Explosive Gases WARNING

13. Carrying Personnel WARNING

14. Boom Angle Indicator

15. Emergency Exit (Enclosed Cab Only)

Note: Many of these hazard related signs are available free of charge by calling JLG Inc. at 1-717-485-5161(Domestic) or 1-877-554-5438(International).

OM11412

Model MMV Rev. 12/04

1.7

Safety Practices

This Page Intentionally Left Blank

1.8

Model MMV Rev. 12/04

Section 2

General Information, Specifications and Maintenance

Contents

PARAGRAPH TITLE PAGE

2.1 MMV Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.2.1 Service Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.2.2 The Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.2.3 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . 2.6

2.2.4 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

2.3.1 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

2.3.2 Bolts and Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

2.3.3 Straight Thread O-ring Fitting (Non-Adjustable) . . . . . . . . . . . . . . . . . . . . 2.7

2.3.4 Straight Thread O-ring Fitting (Adjustable) . . . . . . . . . . . . . . . . . . . . . . . . 2.7

2.3.5 Flat-Face O-ring Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

2.4 Metric Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

2.4.1 Approximate American to Metric Conversions . . . . . . . . . . . . . . . . . . . . . 2.8

2.4.2 Approximate Metric to American Conversions . . . . . . . . . . . . . . . . . . . . . 2.9

2.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

2.5.1 Vehicle Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

2.5.2 Vehicle Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

2.5.3 Attachment Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

2.5.4 Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

2.5.5 Hydraulic Cylinder Performance Specifications . . . . . . . . . . . . . . . . . . . . 2.13

2.5.6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

2.5.7 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

2.5.8 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

2.5.9 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

2.5.10 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

2.5.11 Miscellaneous Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

2.5.12 Tamper Proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

2.5.13 Fork Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

Model MMV Rev. 12/04

2.1

General Information, Specifications and Maintenance

2.6 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

2.6.1 Axles (Differential Housings) and Transfer Case. . . . . . . . . . . . . . . . . . . . 2.20

2.6.2 Wheel Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

2.6.3 Lubrication Points (Grease Fittings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.6.4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.6.5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.6.6 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.6.7 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.6.8 Drive Shaft Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.6.9 General Anti-Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.6.10 Carriage Fork Shafts and Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.6.11 Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.6.12 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.9 Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.9.1 Hose and Tube Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.9.2 Hose and Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.10.1 Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.10.2 Bearing Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.10.3 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.11 Pressure Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.12 After Service Startup and Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.12.1 After Service Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.12.2 After Electrical/Electronic Component Service . . . . . . . . . . . . . . . . . . . . . 2.26

2.12.3 After Hydraulic Component Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

2.12.4 After Brake System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

2.12.5 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

2.12.6 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 2.26

2.12.7 After Tire and Wheel Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.12.8 After Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.12.9 After Boom Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.12.10 After Axle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.2

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.13 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.13.1 Maintenance Schedule and Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.13.2 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

2.13.3 Closed Cab Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

2.13.4 Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

2.13.5 Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

2.13.6 Engine Oil Sample Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37

2.13.7 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37

2.13.8 Engine Fan Belt & Air Conditioner Compressor Belt. . . . . . . . . . . . . . . . . 2.40

2.13.9 Hydraulic System Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.41

2.13.10 Transmission Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.43

2.13.11 Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.45

2.13.12 Brake Disc Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.46

2.13.13 Wheel End Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.48

2.13.14 Transfer Case Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49

2.13.15 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50

2.13.16 Emergency Tire Inflation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50

2.13.17 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54

2.13.18 Fuse and Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56

2.13.19 Boom Wear Pad Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.60

2.13.20 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.61

2.13.21 Boom Chain Tension & Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.64

2.13.22 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.67

2.13.23 Short Term Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.68

2.13.24 Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.68

2.13.25 Counterweight Removal and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 2.70

2.13.26 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.72

2.14 Emergency Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.77

2.14.1 Towing a Disabled Vehicle Short Distances . . . . . . . . . . . . . . . . . . . . . . . 2.77

2.14.2 Towing a Disabled Vehicle Long Distances . . . . . . . . . . . . . . . . . . . . . . . . 2.78

2.14.3 Boom Lowering and Retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.80

2.15 Parking Brake/Transmission De-Clutch Test Procedures . . . . . . . . . . . . . . . . . . 2.81

Model MMV Rev. 12/04

2.3

General Information, Specifications and Maintenance

This Page Intentionally Left Blank

2.4

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.1 MMV COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this manual, it is necessary that the operator/mechanic be familiar with the name and location of the major assemblies on this vehicle. The following illustration identifies the components that are referred to throughout this manual.

Stabilizer

Cylinder

Slave

Cylinders (2)

Rear Door

(Not Visible)

(1 Not Visible)

Boom

Assembly

Operator’s

Protective

Structure

Carriage

Assembly

Engine

Compartment

Frame Sway

Cylinder

Hydraulic

Oil Tank

Lift/Lower

Cylinder

MM1731

Model MMV Rev. 12/04

2.5

General Information, Specifications and Maintenance

2.2 INTRODUCTION

2.2.1 Service Methods

Appropriate service methods and proper repair procedures are essential for safe, reliable operation of this vehicle and the safety of the individual doing the work. This Service Manual provides general direction for accomplishing service and repair work with tested, effective techniques. Following them will assure reliability.

There are many variations in procedures, techniques, tools, and parts for servicing vehicles, as well as work skills. This Manual cannot possibly anticipate all such variations and provide advice or cautions for each one. Accordingly, anyone who intends to depart from the instructions in this Manual must first consider personal safety and then vehicle integrity.

IMPORTANT: JLG recommends the use of environmentally sound waste storage and disposal practices. NEVER drain fluids on the ground or into a sewer or catch basin. Use suitable collection containers, then store and/or dispose of waste products in an approved and safe manner. Check and obey all Federal, State and/ or Local regulations regarding waste storage, disposal and recycling.

2.2.3 Replacement Parts and Warranty Information

For reference when ordering replacement parts or making service inquiries about the vehicle, the vehicle serial number is required to help assure the provision of correct parts and information. Before ordering parts or initiating service inquiries, make note of the serial number.

The vehicle serial number plate (1) is located on the front of the main frame.

2.2.2 The Owners/Operators Manual

The Owners/Operators Manual provides information you need to properly operate and maintain this vehicle.

IMPORTANT: Before you operate this vehicle, read the manual completely and carefully, so that you will understand the safety instructions and the operation of the controls and safety equipment. You must comply with all Danger, Warning, and Caution notices. They are for your benefit.

All references to the right side, left side, front, and rear are given from the operator’s seat looking in a forward direction.

OM1370

IMPORTANT: The replacement of any part on this vehicle with any other than a JLG authorized replacement part can adversely affect the performance, durability, or safety of the vehicle, and will void the warranty. JLG disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.

A warranty registration form must be filled out by the JLG Authorized Service Center (ASC), signed by the purchaser, and returned to JLG when the vehicle is sold and/or put into use.

Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to JLG.

2.2.4 Disclaimer

JLG reserves the right to make changes to and to add im-

provements upon its product at any time, without public notice or obligation. JLG also reserves the right to discontinue manufacturing any product at its discretion at any time.

2.6

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.3 TORQUES

2.3.1 Fasteners

All fasteners (nuts, bolts, washers, etc.) are equal to SAE Grade 5 (PC8.8) and are plated, unless otherwise specified.

2.3.2 Bolts and Nuts

Unless otherwise specified, the following values apply for Grade 5 (PC8.8) nuts and bolts:

Size Torque Size Torque

Inch lb/ft Nm mm Nm lb/ft

1/4 9 12 6.0 10 7

5/16 17 24 8.0 25 18

3/8 31 42 10.0 50 37

7/16 50 68 -- -- --

1/2 75 102 12.0 80 59

9/16 110 150 14.0 130 95

5/8 150 203 16.0 200 146

3/4 250 340 20.0 360 263

7/8 380 515 22.0 510 372

1.0 585 793 24.0 650 475

2.3.3 Straight Thread O-ring Fitting (Non-Adjustable)

When the vehicle leaves the factory, it is equipped only with straight thread o-ring fittings. Customer-added accessories may differ; therefore, consult the manufacturer’s product literature for information.

1. Verify that both threads and sealing surfaces are free of burrs, nicks, scratches, and any foreign material.

2. Lubricate the new o-ring with a light coating of hydraulic oil.

3. Tighten fitting to the proper torque according to the following chart:

SAE Size

4 6

8 10 12 16 20 24

15-17 34-36

58-62 100-110 134-146 202-218 248-272 303-327

Torque

lb/ft Nm

20-23 46-49

79-84 136-149 181-198 274-296 336-369 411-443

2.3.4 Straight Thread O-ring Fitting (Adjustable)

1. Verify that both mating parts are free of burrs, nicks, scratches, and any foreign material.

2. Lubricate the new o-ring with a light coat of hydraulic oil.

3. Back off the locknut as far as possible.

4. Screw the fitting into the port by hand until the backup washer contacts the face of the port and is pushed all the way towards the locknut.

5. To position the fitting, unscrew by the required amount, but not more than one full turn.

6. Hold the fitting in the desired position and tighten to the proper torque according to the following chart:

Adjustable Straight-Thread O-ring

Fitting Torque Chart

SAE Size

4 6

8 10 12 16 20 24

15-17 34-36

58-62 100-110 134-146 202-218 248-272 303-327

Torque

lb/ft Nm

20-23 46-49

79-84 136-149 181-198 274-296 336-369 411-443

Model MMV Rev. 12/04

2.7

General Information, Specifications and Maintenance

2.3.5 Flat-Face O-ring Fittings

Improper assembly of this type of joint will result in a leaking joint. Under tightening will result in the joint loosening during normal use. Foreign material on either sealing surfaces will cause damage to one or both mating parts when the joint is tightened, resulting in a leaking joint. The absence of the fitting o-ring will cause the joint to leak.

1. Verify that both threads and sealing surfaces are free of burrs, nicks, scratches, and any foreign material.

2. Inspect the male fitting for the presence of the o-ring seal. Replace the o-ring if missing or damaged.

3. Place the flat surface of the female connector in full contact with the o-ring in the male connector.

4. Finger tighten the nut onto the fitting.

5. Hold the fitting in the desired position, for hoses and swivel fittings, use a second wrench to keep the female connector from moving during tightening. Tighten to the proper torque according to the following chart:

SAE Size

4 6

8 10 12 16 20 24

19-36 28-54 42-80

65-126 100-180 130-240 150-280 175-330

Torque

lb/ft Nm

26-49

38-73 57-108 88-171

136-244 176-325 203-380 237-447

2.4 METRIC CONVERSION FACTORS

2.4.1 Approximate American to Metric Conversions

When this is known Multiply by To Find

TORQUE (moment of force)

Pound/feet (lb/ft) 1.356 Newton meters (Nm)

Pound/inches (lb/in) 0.113 Newton meters (Nm)

POWER

Horsepower (hp) 745.7 Watts

SPEED (velocity)

Miles per hour (mph) 1.609 Kilometers per hour

(km/hr; kph)

LENGTH (distance)

Inches (in) 25.4 Millimeters (mm)

Inches (in) 2.5 Centimeters (cm)

Feet (ft) 30.5 Centimeters (cm)

Feet (ft) 0.305 Meters (m)

Yards (yd) 0.9 Meters (m)

Miles (mi) 1.6 Kilometers (km)

AREA

Square inches (in

Square feet (ft

Square yards (yd

Square miles (mi

Acres 0.4 Hectares (ha)

MASS (weight)

Ounces (oz) 28.3 Grams (g)

Pounds (lb) 0.4536 Kilograms (kg)

Short tons (2000 lb) 0.9 Metric ton (t)

) 6.5 Square centimeters (cm2)

) 0.09 Square meters (m2)

) 0.8 Square meters (m2)

) 2.6 Square kilometers (km2)

2.8

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

VOLUME

Teaspoons (tsp) 5 Milliliters (ml)

Tablespoons (Tbsp) 15 Milliliters (ml)

Cubic inches (in

) 16 Milliliters (ml)

Fluid ounces (fl oz) 30 Milliliters (ml)

Cups (c) 0.24 Liters

Pints (pt) 0.47 Liters

Quarts (qt) 0.95 Liters

Gallons (gal) 3.8 Liters

Cubic feet (ft

Cubic yards (yd

) 0.03 Cubic meters (m3)

) 0.76 Cubic meters (m3)

AIR PRESSURE

Pounds per square inch (psi) 6.895 Kilopascals (kPa)

HYDRAULIC PRESSURE

Pounds per square inch (psi) 0.069 Bar

TEMPERATURE (exact)

To determine degrees Celsius (° C), subtract 32, then multiply by 0.56; (° F -32) x 0.56 = ° C.

2.4.2 Approximate Metric to American Conversions

When this is known Multiply by To Find

TORQUE (moment of force)

Newton meters (Nm) 0,738 Pounds/feet (lb/ft)

Newton meters (Nm) 8,85 Pounds/inches (lb/in)

POWER

Watts 0,0013 Horsepower (hp)

SPEED (velocity)

Kilometers per hour (km/hr; kph) 0,621 Miles per hour (mph)

LENGTH (distance)

Millimeters (mm) 0,0394 Inches (in)

Centimeters (cm) 0,394 Inches (in)

Meters (m) 3,281 Feet (ft)

Meters (m) 1,1 Yards (yd)

Kilometers (km) 0,621 Miles (mi)

AREA

Square centimeters

) 0,4 Square inches (in2)

(cm

Square meters (m

) 1,1 Square yards (yd2)

Square kilometers

(km

) 0,6 Square miles (mi2)

Hectares (10000 m

)2,5 Acres

MASS (weight)

Grams (g) 0,035 Ounces (oz)

Kilograms (kg) 2,2 Pounds (lb)

Metric ton

(1000 kg) (t) 1,1 Short tons

VOLUME

Milliliters (ml) 0,03 Fluid ounces (fl oz)

Milliliters (ml) 0,06 Cubic inches (in

)

Liters 2,1 Pints (pt)

Liters 1,06 Quarts (qt)

Liters 0,26 Gallons (gal)

Cubic meters (m

) 35 Cubic feet (ft3)

) 1,3 Cubic yards (yd3)

AIR PRESSURE

Kilopascals (kPa) 0,145 Pounds per square

inch (psi)

HYDRAULIC PRESSURE

Bar 14,5 Pounds per square

inch (psi)

TEMPERATURE (exact)

To determine degrees Fahrenheit (° F), multiply degrees Celsius (° C) by 1.8, then add 32; (° C x 1.8) + 32 = ° F.

Model MMV Rev. 12/04

2.9

General Information, Specifications and Maintenance

2.5 SPECIFICATIONS

2.5.1 Vehicle Dimensions

With 15.50-25 Radial Tires

Description Specifications

(A) Length (without Forks) 248" (6.299 mm)

(B) Width 101" (2.565 mm)

(D) Wheelbase 131" (3.327 mm)

(E) Tread Center 84" (2.134 mm)

(F) Ground Clearance

(at the bottom of the hydraulic reservoir drain plug)

(G) Turning Radius, Curb to Curb 32.5' (9,91 m)

(H) Turning Radius, Clearance 45.5' (13,9 m)

(I) Maximum Lift Height, Boom Extended 42' 4" (12,9 m)

(J) Maximum Lift Height, Boom Retracted 20' 3" (6,2 m)

(K) Maximum Below Grade Depth, Boom Extended 1' 8" (0,5 m)

(L) Maximum Reach, from Front of Front Tires 30' (9,1 m)

(M) Maximum Reach at Maximum Lift Angle, Boom Extended 6' 2" (1,9 m)

(N) Maximum Reach at Maximum Lift Angle, Boom Retracted -2' 8" (-0,8 m)

(O) Maximum Reach at Minimum Lift Angle, Boom Extended 29' (8,8 m)

(P) Maximum Boom Lift Angle 70.0°

(Q) Minimum Boom Lift Angle -2.9°

(R) Percentage of Slope of Approach >45°

(S) Percentage of Slope of Departure >45°

Fork Tilt Angle:

(T) At Maximum Boom Angle - UP 84.0°

15.1" (383 mm)

(U) At Maximum Boom Angle - DOWN -23.4°

(V) At Minimum Boom Angle - UP 12.2°

(W) At Minimum Boom Angle - DOWN -30.3°

Frame Sway Angle (Not Shown):

Right 10.0°

Left 10.0°

2.10

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

0.0

Model MMV Rev. 12/04

G & H

MM2230

2.11

General Information, Specifications and Maintenance

2.5.2 Vehicle Weights

Vehicle Configuration Front Axle Rear Axle Total

Without Carriage 9,250 lbs

(4.196 Kg)

With 11K Carriage 11,200 lbs

(5.080 Kg)

With 7K Carriage 12,900 lbs

(5.851 Kg)

With Both Carriages 14,800 lbs

(6.713 Kg)

Working Weight (Vehicle working weight is figured with one of the configurations listed above, 25%-full fuel tank, and radial tires [no hydrofill]):

Operating Load 7K Carriage 7,000 lbs

Operating Load 11K Carriage 11,000 lbs

17,650 lbs (8.006 Kg)

16,900 lbs (7.666 Kg)

16,400 lbs (7.439 Kg)

15,700 lbs (7.122 Kg)

26,900 lbs

(12.202 Kg)

28,100 lbs

(12.746 Kg)

29,300 lbs

(13.290 Kg)

30,500 lbs

(13.835 Kg)

(3.175 Kg)

(4.989 Kg)

2.5.3 Attachment Weights

Description Weight

7K Carriage 2,300 lb (1.043 kg)

11K Carriage 1,300 lb (590 kg)

2.5.4 Performance Specifications

Description Speed

Travel Speed (Radial Tires, No Load):

First Gear 3.5 mph (5,6 km/hr)

Second Gear 5.7 mph (9,2 km/hr)

Third Gear 13.5 mph (21,7 km/hr)

Fourth Gear 19.4 mph (31,2 km/hr)

2.12

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.5.5 Hydraulic Cylinder Performance Specifications

Note: Vehicle with no load, engine at full throttle, hydraulic oil warm (80° F [27° C] minimum), engine at operating

temperature

Function Approximate Times,

in Seconds

7K Carriage

Boom Extend 17.00 17.00

Boom Retract 23.60 23.60

Boom Lift Retracted 17.50 17.50

Boom Lower Retracted 19.80 19.80

Attachment Tilt - UP 7.60 7.60

Attachment Tilt - DOWN 7.30 7.30

Frame Sway Left to Right with Boom Down *12.00 to 15.50 *12.00 to 15.50

Frame Sway Left to Right with Boom Above 40° and Emergency Brake Engaged

Frame Sway Right to Left with Boom Down *12.00 to 15.50 *12.00 to 15.50

Frame Sway Right to Left with Boom Above 40° and Emergency Brake Engaged

Fork Side Shift

Left Cylinder, Right to Left 13.00 13.30

Left Cylinder, Left to Right 22.00 11.40

*17.50 to 33.40 *17.50 to 33.40

*21.50 to 43.00 *21.50 to 43.00

Approximate Times,

in Seconds

11K Carriage

Right Cylinder, Right to Left 13.00 13.30

Right Cylinder, Left to Right 22.00 11.40

* All times listed are approximate MAXIMUM times except where noted. Noted times are given

as a minimum to maximum range.

Model MMV Rev. 12/04

2.13

General Information, Specifications and Maintenance

2.5.6 Electrical System

Description Specifications

Battery:

Type, Rating 12 VDC, Negative (-) Ground, Maintenance Free

Quantity 2

Reserve Capacity 1225 Cold Cranking amps @ 0° F (-18° C)

Group/Series HASP-FT

Alternator 24V/70 amps

Fuses - Standard Blade Style:

Switch Lamps, Service Brake, Hourmeter 2 amps

LMI System 3 amps

Fuel Shut-off Solenoid (FSOS), Transmission Gear,

5 amps

Transmission Direction, Steer Mode, Parking Brake

Joystick Logic Panel, Horn, Front Wiper/Washer, Top Wiper/

7.5 amps

Washer, Rear Wiper, Left Fork Shift, Right Fork Shift

Front Dash Display Panel, Ignition Pre-heat, Air Conditioner

15 amps

Condenser Fan Motor

Heater, Normal Lights, Blackout Lights 25 amps

Main, Power Window 30 amps

Fuses -

Battery Equalizer 125 amps

Circuit Breaker

Ignition Switch 12 volt/ 50 amp

Relays:

Neutral Engage Relay 12 volt

Work Light Power Relay 24 volt

High Beam Power Relay 24 volt

Brake Light Relay 12 volt

Light Power Relay 12 volt

Blackout Ignition Relay 12 volt

Normal Lights Ignition Relay 12 volt

Reverse Signal Relay 12 volt

Door Window Relay 12 volt

Closed Cab Accessory Power Relay 12 volt

Fuel Shut Off Solenoid Relay 12 volt

Air Conditioner Condenser Fan 12 volt

2.14

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.5.7 Engine Performance Specifications

Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting.

Description Specifications

Engine Make/Model Cummins Turbo/4BTA3.9

Displacement 239 in

Horsepower 116 HP @ 2500 rpm

Number of Cylinders 4

Engine High Idle with No Load 2750 ±100

Engine Low Idle 1050 ±50 rpm

Fuel Delivery Fuel Injection

Air Cleaner Dry Type, Replaceable Primary and

Peak Torque 407 lb/ft @ 1500 rpm

Average Fuel Consumption, Depending on Load/Duty 2.67 gal/hr (2,22 Imp gal/hr, or 10,1 l/hr)

(3.9 liters)

Safety Elements

Model MMV Rev. 12/04

2.15

General Information, Specifications and Maintenance

2.5.8 Fluid and Lubricant Capacities

Fluid & Lubricant Description Specifications

Engine Crankcase Oil:

Capacity with Filter Change 13.3 qt (12,6 liters)

Filter Capacity 1.3 qt (1,2 liters)

Oil Type (Refer to

Fuel Tank:

Total Capacity 35.5 gal (134 liters)

Usable Capacity 33.5 gal (127 liters)

Type of Fuel Above 32° F (0° C) Standard No. 2 Diesel. (Refer to

Type of Fuel Below 32° F (0° C) 50/50 Mix of #1 and #2 Diesel Fuels. (Refer to

Alternate Fuel JP-5, JP-8 and Jet A-1

Cooling System:

Capacity w/o Heater (including 1.5 qt [1,4 liters] for overflow bottle)

Overflow Bottle Capacity 3.0 qt (2,8 liters)

Type of Fluid 50/50-mix of ethylene glycol and water. (Refer to

Transmission:

Capacity w/Filter Change 12 qt (11,4 liters)

Section 2.6.5, Engine

Above 23° F (-5° C) use SAE 15W40 Diesel Engine Oil.

23° F (-5° C) to -25° F (-32° C) use 5W30 Below -25° F (-32° C) use 0W30 Oil Meeting MIL-PRF-2104G Specifications is Also acceptable

Section 2.6.5, Engine

12.5 qt (11,8 liters)

Section 2.6.5, Engine

Filter Capacity 1 qt (1 liter)

Typ e o f O i l (Refer to

sion

Transfer Case:

Capacity 1.5 qt (1,4 liters)

Typ e o f O i l (Refer to

Section 2.6.6, Transmis-

Section 2.6.1, Axles (Differential Housings) and Transfer Case

Axle (Differential Housing):

Capacity 10.5 qt (10,0 liters)

Typ e o f O i l (Refer to

Section 2.6.1, Axles (Differential Housings) and Transfer Case

2.16

Above 125° F (50° C) Use MIL-PRF-2104G Grade 15W40 14° F (-10° C) to 125° F (50° C) use MIL-PRF-2104G Grade 10W30 (Universal Tractor Fluid) Below 14° F (-10° C) use DEXRON lll (Automatic Transmission Fluid)

Above 100° F (38° C) use MIL-PRF-2104G Grade 15W40 Below 100° F (38° C) use MIL-PRF-2104G Grade 10W30 (Universal Tractor Fluid)

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

Fluid & Lubricant Description Specifications

Axle (Wheel Ends):

Capacity 1.3 qt (41.6 fl oz, or 1,2 liters)

Type of Oil (Refer to

Section 2.6.1, Axles (Differential Housings) and Transfer Case

Hydraulic System:

System Capacity 41.3 gal (156 liters)

Reservoir Capacity 28.5 gal (108 liters)

Type of Oil (Refer to

System

Section 2.6.4, Hydraulic

Above 100° F (38° C) use MIL-PRF-2104G Grade 15W40 Below 100° F (38° C) use MIL-PRF-2104G Grade 10W30 (Universal Tractor Fluid)

14° F (-10° C) & Above use MIL-PRF-2104G Grade 10 Hydraulic Oil 125° F (50° C) & Below use DEXRON lll (Automatic Transmission Fluid)

2.5.9 Hydraulic System

Description Specifications

Valve Relief Settings:

Main System Relief 3500 ±100 psi (241 ±6,9 bar)

Port Relief Boom - Hoist/Lower/Extend/Retract 3200 ±100 psi (220,6 ±6,9 bar)

Port Relief Fork Tilt (Both Sides) 3500 ±100 psi (241 ±6,9 bar)

Stabilizer Cylinder 75-150 psi (5,2-10,3 bar)

Power Steering Relief 2500 ±100 psi (172,3 ±7 bar)

Standby Pressure 200 ±50 psi (13,8 ±3,4 bar)

Pilot Pressure 550 ±100 psi (37,9 ±7 bar)

Parking Brake Relief 650 ±50 psi (44.8 ±3,4 bar)

Model MMV Rev. 12/04

2.17

General Information, Specifications and Maintenance

2.5.10 Tires

Description Specifications

Tire Size 15.5R25, L-2, (2 Star Minimum) Radial

Wheel Lug Nut Torque 430-470 lb/ft (583-637 Nm)

Air Pressure 87 psi (600 kPa)

Tire Footprint Area (area is established under max. tip load):

Vehicle with 7K Carriage with No Load (15.5R25, L-2, 2 Star tires at specified air pressure):

Vehicle with 7K Carriage with Rated Load (15.5R25, L-2, 2 Star tires at specified air pressure):

Vehicle with 11K Carriage with No Load (15.5R25, L-2, 2 Star tires at specified air pressure):

Vehicle with 11K Carriage with Rated Load (15.5R25, L-2, 2 Star tires at specified air pressure):

Maximum Ground Pressure (maximum ground pressure at tip = (machine weight + load) / (2 x footprint area):

126 in

183 in

129 in

209 in

(810 cm2)

(1.180 cm2)

(835 cm2)

(1.350 cm2)

Vehicle with 7K Carriage with No Load (15.5R25, L-2, 2 Star tires at specified air pressure):

Vehicle with 7K Carriage with Rated Load (15.5R25, L-2, 2 Star tires at specified air pressure):

Vehicle with 11K Carriage with No Load (15.5R25, L-2, 2 Star tires at specified air pressure):

Vehicle with 11K Carriage with Rated Load (15.5R25, L-2, 2 Star tires at specified air pressure):

2.5.11 Miscellaneous Specifications

Description Specifications

Steering Wheel:

Maximum Number of Turns, Lock to Lock 4.25 turns

Minimum Number of Turns, Lock to Lock 3.75 turns

156 psi (1.070 kPa)

174 psi (1.200 kPa)

152 psi (1.050 kPa)

185 psi (1.275 kPa)

2.18

Model MMV Rev. 12/04

2.5.12 Tamper Proofing

General Information, Specifications and Maintenance

A tamper-proof means is in place on the following adjustable components prior to machine shipment. This can either be tamper-proof paint, or a steel tamper-proof cap. DO NOT attempt to defeat, by-pass or alter any tamper-proof device.

• Main Valve Port Relief Valves [5]

• Fork Cylinder Counterbalance Valves [2]

• Secondary Function Manifold Valves [2]

• Unloader Valve [2]

• Main System Relief Valve [1]

2.5.13 Fork Ratings

All approved forks for this vehicle are marked with a maximum load capacity rating. This rating (1) is stamped on the right edge of the fork just below the fork pivot shaft (2). The rating is listed in U.S. pounds and based upon a 24" (610 mm) load center (3) (11K carriage) or 48" (1219 mm) load center (3) (7K carriage). This rating specifies the maximum load capacity that the individual fork can safely carry at the maximum specified load center.

Since forks are always used in multiples, the total rating of any combination of forks will be the sum of their rated capacity. All forks should be used in matched pairs.

WARNING: DO NOT exceed the

total rated capacity of the specific pair of forks being used. Forks can break causing loss of load and possible death or serious personal injury to the operator or personnel in the area. If the total rated capacity of the forks exceeds the capacity of the vehicle, the vehicle capacity should not be exceeded.

The maximum load capacity for this vehicle is 7,000 pounds (3.175 Kg) for the 7K carriage or 11,000 pounds (4.989 Kg) for the 11K carriage. The matched pair or set of forks used on this vehicle should have total load ratings which equal or exceed these weights. When the load rating of the vehicle differs from the load capacity of the forks, the lower value becomes the overall load capacity.

Model MMV Rev. 12/04

OM0941

2.19

General Information, Specifications and Maintenance

2.6 FLUIDS, LUBRICANTS AND CAPACITIES

2.6.1 Axles (Differential Housings) and

Transfer Case

a. Axle and Transfer Case Lubricants

Recommended Oil/Temperature Range

MIL-PRF-2104G Grade 15W40

MIL-PRF-2104G Grade 10W30

(Universal Tractor Fluid*)

100° F (38° C)

*John Deere (JDM J20C Hy-Gard) *Ford/New Holland ESN-M2C134-D (Hydraulic Oil 134) *Massey Ferguson M-1141 (Permatran lll) *Chevron 1000 THF

In general, use a oil that meets the following specifications:

Nominal viscosity at 104° F (40° C)....................... 55 cSt

Minimum viscosity at 212° F (100° C) .................. 9.1 cSt

Pour point (Maximum) .............................. -32° F (-36° C)

Flash point (Minimum) ............................ 392° F (200° C)

Minimum viscosity index ............................................ 135

b. Axle and Transfer Case Capacities

Axles (differential housings) .............. 10.5 qt (10,0 liters)

Transfer case......................................... 1.5 qt (1,4 liters)

OM1680

2.6.2 Wheel Ends

a. Wheel-End Lubricants

Recommended Oil/Temperature Range

MIL-PRF-2104G Grade 15W40

MIL-PRF-2104G Grade 10W30

(Universal Tractor Fluid*)

100° F (38° C)

*John Deere (JDM J20C Hy-Gard) *Ford/New Holland ESN-M2C134-D (Hydraulic Oil 134) *Massey Ferguson M-1141 (Permatran lll) *Chevron 1000 THF

In general, use a oil that meets the following specifications:

Nominal viscosity at 104° F (40° C) ...................... 55 cSt

Minimum viscosity at 212° F (10° C) .................... 9.1 cSt

Pour point (Maximum).............................. -32° F (-36° C)

Flash point (Minimum).............................392° F (200° C)

Minimum viscosity index ............................................135

DO NOT add additional friction modifier to factory-filled wheel ends. All wheel ends are factory-filled by the manufacturer with oil. If a wheel end is drained for service, it should be refilled with the gear oils listed.

Note: DO NOT use synthetic oil without the express written consent of the manufacturer.

b. Wheel-End Capacity

Wheel ends .......................1.3 qt (41.6 fl oz, or 1,2 liters)

OM1680

2.20

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.6.3 Lubrication Points (Grease Fittings)

Lubricants

When lubricating any component via the grease fittings, use multi-purpose lithium-based grease with EP additives that meets NLGI Grade 2 specifications. Products known to meet these requirements include:

• AMOCO AMOLITH EP2

• ARCO LITHOLINE EP2

• BENZ MOLY-SERVICE EP2

• CHEVRON DUROLITH EP2

•CITGO H EP2

• GULF GULFCROWN EP2

• MOBILE MOBILUX EP2

• SHELL ALVANIA EP2

• SUN PRESTIGE 742EP

• TEXACO MULTIFAX EP2

Note: Refer to Section 2.13.1, Maintenance Schedule and Checklist for lubrication intervals and grease fitting locations.

2.6.4 Hydraulic System

a. Hydraulic Fluids

Recommended Oil/Temperature Range

MIL-PRF-2104G Grade 10

(Automatic Transmission Fluid)

DEXRON lll

14° F (-10° C)

125° F (50° C)

OM1700

2.6.5 Engine

a. Engine Fluids and Lubricants

1. Engine oil:

Recommended Oil/Temperature Range

MIL-PRF-2104G Grade 15W40 (SAE 15W40)

MIL-PRF-2104G

Grade 5W30 (SAE 5W30)

MIL-PRF-2104G Grade 0W30 (SAE 0W30)

-25° F (-32° C)

2. Cooling system (engine coolant):

In general, use a 50/50-mix of premium-quality ethylene glycol (commonly referred to as “anti-freeze/anti-boil over”) and water. Additives are not necessary.

3. Fuel:

In general, use No. 2 diesel fuel. From November 15 to March 15 when operating in cooler climates where ambient (outside air) temperatures are consistently at or below 32° F (0° C), use a 50/50 mix of #1 and #2 diesel fuels. Use good quality diesel fuel and change the fuel filter regularly. Additives are not necessary.

The vehicle is also capable of operation on alternate military fuels including JP-5, JP-8 and Jet A-1. However, an up to 5% reduction in engine horsepower output can be expected when using alternate military fuels due to the lower BTU rating of these fuels.

23° F (-5° C)

OM1710

The hydraulic system is factory filled hydraulic oil that meets the requirements of U.S. ordinance specification MIL-PRF-2104G. When filling the hydraulic system, use only an oil that meets these requirements or a grade10 oil that meets the requirements of U.S. ordinance specification MIL-PRF-2104G.

b. Hydraulic System Capacity

System capacity ................................41.3 gal (156 liters)

Reservoir capacity.............................28.5 gal (108 liters)

Model MMV Rev. 12/04

2.21

General Information, Specifications and Maintenance

b. Engine Capacities

1. Engine Oil Capacity

Capacity w/filter change .................... 13.3 qt (12,6 liters)

Filter....................................................... 1.3 qt (1,2 liters)

2. Cooling System Capacity

Capacity............................................. 12.5 qt (11,8 liters)

Overflow bottle capacity ........................ 3.0 qt (2,8 liters)

3. Fuel Tank Capacity

Total capacity ....................................35.5 gal (134 liters)

Usable capacity .................................33.5 gal (127 liters)

2.6.6 Transmission

a. Transmission Fluid

Recommended Oil/Temperature Range

MIL-PRF-2104G Grade 15W40

MIL-PRF-2104G

Grade 10W30

(Universal Tractor Fluid*)

DEXRON lll

(Automatic

Transmission Fluid)

14° F (-10° C)

*John Deere (JDM J20C Hy-Gard) *Ford/New Holland ESN-M2C134-D (Hydraulic Oil 134) *Massey Ferguson M-1141 (Permatran lll) *Chevron 1000 THF

In general, use a oil that meets the following specifications:

Nominal viscosity at 10° F (40° C)......................... 55 cSt

Minimum viscosity at 212° F (100° C) .................. 9.1 cSt

Pour point (Maximum) .............................. -32° F (-36° C)

Flash point (Minimum) ............................ 392° F (200° C)

Minimum viscosity index ............................................ 135

125° F (50° C)

OM1690

2.6.7 Air Conditioning

a. Air Conditioning Fluid

Type ...................................................................... R134a

b. Air Conditioning System Capacity

System Capacity ...................................... 3.0 lbs (1,4 kg)

2.6.8 Drive Shaft Splines

IMPORTANT: DO NOT disassemble any of the drive

shafts (refer to Section 6, Transfer Case and Drive Shafts of this manual for information covering drive shafts and U-joints). To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly. Refer to the appropriate parts manual for ordering information.

Respective of the above statement, should it become necessary to coat the transmission input drive shaft splines, use molybdenum disulfide grease. Molybdenum disulfide grease specifically formulated for this purpose is marketed by several manufacturers under various names, including:

Aldrich Chemical Co., Inc.

Product name:

Catalog Number 23,484-2 Package Size: 5 g (0.175 oz) 100 g (3.5 oz) 500 g (17.5 oz)

Contact:

Aldrich Chemical Co., Inc. P.O. Box 335 Milwaukee, WI 53201 USA Phone: (414) 273-3850

DOW CORNING INC.

Product name:

Contact:

Dow Corning Corporate Center P.O. Box 994 Midland, MI 48686-0994 USA Phone: (517) 496-4400

Aldrich MOLYBDENUM (IV) SULFIDE

MOLYKOTE® 77 Paste

b. Transmission Capacity

Capacity w/filter change ................ 12 quarts (11,4 liters)

Filter............................................................... 1 qt (1 liter)

2.22

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.6.9 General Anti-Corrosion

a. Anti-Corrosion Compound

For general anti-corrosion protection, use a wax film rust inhibitor that provides a protective film two tenthousandths of an inch (0.0002" or 0,00005 mm) thick. One such rust inhibitor that is specifically formulated for this purpose is

LPS 3

. It is marketed by:

LPS Laboratories, Inc. 4647 Hugh Howell Rd. Tucker, GA 30085-5052 USA Phone: 1-800-241-8334 Fax: (770) 493-9206

Note: Anti-corrosion protection is especially important in frame and stabilizer cylinder pin support bores for protection from fretting corrosion wear.

b. Anti-Corrosion Need Areas

Coat all unplated pins and all bores for cylinder pins, attachment pivot pins, chain sheave pins, the quick attach lock pin, and all quick attach lock pin bores. On the boom, coat the fork shaft and unpainted boom slide pathways.

2.6.10 Carriage Fork Shafts and Wear Pads

OM09402

2.6.11 Paint

Unless otherwise specified, paint components as indicated in the following sections.

a. Military Paint (CARC)

Durable, premium military paint is available in a production-sized one gallon (3,8 liters) container for extensive repainting. Consult the appropriate parts manual for the applicable part number and ordering information. Use military paint on all vehicle components except as specified in paragraph

b. Black Paint

Durable, premium black paint is available in both a convenient 16-ounce (480 ml) spray can for touch-ups, and in a production-sized one gallon (3,8 liters) container for extensive repainting. Consult the appropriate parts manual for the applicable part number and ordering information.

• Boom Angle Indicator Pointer

• Brake Pedal

•Radiator

• Seat Adapter Plate

• Radiator Shroud

• Transmission Oil Cooler

• Drive Shafts

• Transfer Case

•Forks

• Mirrors and Mirror Brackets

• Steering Column

• Wheels

• Air Conditioner Condenser

• Air Conditioner Condenser Guard

2.6.11, b

Use ONLY Teflon Lube to coat the entire fork shaft (1) and the wear bar (2). DO NOT apply grease or any other type of petroleum based lubricant to these areas. Grease and petroleum based lubricants attract debris which will prematurely wear the fork bushings and/or wear pads.

Apply Teflon Lube as needed to keep forks sliding side-to-side smoothly, when putting vehicle into storage or when Teflon Lube appears to be worn off or rust starts to appear on the fork shaft or wear bar.

Model MMV Rev. 12/04

2.6.12 Thread Locking Compound

For general thread-locking purposes, Loctite® products, manufactured by Loctite Corporation, are recommended.

Contact:

Loctite Corporation 1001 Trout Brook Crossing Rocky Hill, CT 06067 USA Phone: 1-800-LOCTITE (1-800-562-8483) FAX: (860) 571-2460 Internet: http://www.loctite.com

Loctite

is a registered trademark of Loctite Corporation.

2.23

General Information, Specifications and Maintenance

2.7 CLEANING

Dirt and abrasive dust reduce the efficient working life of parts and systems, and lead to the costly replacement of components. To help increase the service life of parts, clean the exterior of all parts before beginning any repairs.

Use cleaning fluids and solvents suitable for cleaning parts that do not create safety hazards. Certain types of cleaning fluids can cause skin irritation and damage to components (such as rubber, electrical parts, etc.).

Servicing the hydraulic system in particular requires cleanliness.

Follow these precautions before attempting to service any hydraulic component:

1. Flush hose and tube assemblies with a solvent compatible with hose materials. Blow excess solvent away with shop air.

2. Cap hydraulic fittings, hoses and tube assemblies, and protect threads until time of installation. Clean up any hydraulic fluid spillage immediately.

3. Flush hydraulic reservoir, fuel tank, and gear housing with a suitable solvent to remove paint, metal chips, etc.

4. Protect hydraulic system components from airborne contaminants. Plug all cylinder, valve, reservoir, tank and pump openings until time of installation.

5. Use clean, filtered oil when filling the system. Maintain the hydraulic system at a minimum cleanliness level of ISO code 18/15-particle ration count.

2.8 REPLACEMENT

ALWAYS use the correct tool when removing or replacing any part or performing any service.

Some procedures may require the use of specialized tools. If needed, many of these tools can be obtained through Snap-on

Contact:

Snap-on Incorporated P.O. Box 1410 Kenosha, WI 53141-1410 USA Phone: 1-262-656-5200 Internet: http://www.snapon.com

Snap-on ogies, Inc.

Replace o-rings, seals, and gaskets whenever they are disturbed. NEVER mix new and old seals or o-rings, regardless of apparent visual condition. ALWAYS lubricate new seals and o-rings with hydraulic oil before installation.

is a registered trademark of Snap-on Technol-

tool distributors.

2.9 HOSES AND TUBES

2.9.1 Hose and Tube Inspection

1. Damaged, dented, crushed, or leaking hose and tube fittings restrict oil flow and the operation of the system being served. Fittings showing signs of movement from their original position have failed and must be replaced. ALWAYS replace the entire hose or tube assembly if the fittings are damaged.

2. Hoses must remain in good condition. Obvious signs of external hose wear or hydraulic fluid leaking or weeping indicates the need to replace the hose assembly. If in doubt, replace the hose.

3. Replace if any of the following conditions exist:

• Ballooning (replace hose immediately!)

• Kinking, crushing, stretching or deforming

• Concealed corrosion of wire reinforcement

• Chafed outer cover

2.9.2 Hose and Tube Installation

1. When installing a new hose, loosely connect each end and verify that the hose takes up the designed position before tightening the connection completely. Tighten clamps sufficiently to hold the hose without crushing it, and to prevent movement and chafing.

2. If a hose is replaced on a moving part, move the part through its entire range of motion to verify that the hose will not incur damage. Adjust as necessary.

3. When installing any hose, verify that it does not become kinked or twisted.

4. NEVER allow freely moving or unsupported hoses to contact each other or a related work surface. Such contact causes chafing and reduces hose life.

2.24

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.10 BEARINGS

2.10.1 Bearing Removal

1. NEVER remove bearings unless absolutely necessary! Always use the recommended puller to reduce the risk of bearing or related component damage.

2. When bearings or bushings are removed, verify that the bearing or bushing is free from discoloration, nicks, scuffing, and signs of overheating. If in doubt, replace the bearing or bushing.

2.10.2 Bearing Cleaning

Wear safety glasses. Clean bearings acceptable for service in a suitable solvent. NEVER spin-dry a bearing with compressed air; this can cause metal-to-metal contact and bearing damage. Compressed air can also cause a bearing to come apart. After cleaning a bearing, immerse it in clean lubricating oil until needed.

2.10.3 Bearing Installation

1. Always install bearings carefully to help avoid damaging their delicate surfaces.

2. Install bearings using one of the following methods:

• PRESS FIT for installation on rotating parts such as shafts and gears;

• PUSH FIT into static locations such as reduction gear housings.

3. Always install the bearing into the rotating part first whenever possible.

4. Use a press or the proper installation tools when installing a bearing or bushing.

5. In the absence of a press or proper installation tools, carefully heat the casing and/or bearing in hot oil to assist in the installation.

2.11 PRESSURE TESTING AND ADJUSTMENT

Prior to pressure testing or adjustment, verify that all hoses and tubes are in good condition and that all fittings are tight.

Use pressure gauges with the proper ranges and ratings to measure the specified pressures.

Use correct test procedures to help prevent personal injury, damage to the system or test equipment.

Verify that the hydraulic oil is at proper operating temperature, 80-120° F (27-49° C), before adjusting the pressure reducing valve, or relief valves. If necessary, operate the vehicle to raise the oil temperature. In the absence of a temperature gauge, the oil temperature can be checked by placing a hand against the side or the bottom of the reservoir; if the tank is too hot to keep the hand in contact with it, the oil temperature should be within the proper range.

2.12 AFTER SERVICE STARTUP AND CHECKS

2.12.1 After Service Startup

Note: Refer to the Owners/Operators Manual for engine

cold-start procedures.

1. Check fluid levels.

2. Connect the negative (-) battery cable to the battery (if it is disconnected).

3. Start and idle engine. Check for leaks from hydraulic components, engine, axles, transmission, brakes and reservoirs or tanks. Check the levels of all fluids and lubricants.

4. Purge the hydraulic system of air by operating all vehicle functions through their entire range of motion several times.

5. Check for proper operation of all components.

6. Retract all cylinders fully. Turn the engine OFF and check the hydraulic reservoir level. Recheck the level when the hydraulic oil is cold.

7. Replace the hydraulic filter if required.

Model MMV Rev. 12/04

2.25

General Information, Specifications and Maintenance

2.12.2 After Electrical/Electronic Component Service

1. Check the torque of all fasteners securing replaced electrical/electronic components.

2. Check wiring connections to components.

3. Verify that wiring components are dry and free of moisture.

4. Check connectors for broken, frayed, or loose wires.

5. Check for brittle or frayed wire shielding.

6. Connect the negative (-) battery cable terminal to the battery (if it is disconnected).

7. Check the operation of the replaced component(s).

2.12.3 After Hydraulic Component Service

1. Check torque of fasteners on replaced components.

2. Check that hoses and tubes are properly attached, positioned, and tightly connected.

3. If a hydraulic component failed and contaminated the system, flush the system, clean the hydraulic oil reservoir (tank), and replace the hydraulic oil filter.

4. After normal hydraulic component maintenance, check the hydraulic fluid level and add fluid as required.

5. Start engine and bleed hydraulic system of air. Operate all boom functions through their full range of motion several times. Cycle the hoist and extend cylinders to bleed air from the system. Visually check for leaks.

6. Check operation of all systems in the hydraulic circuit by operating the controls through all functions several times.

2.12.4 After Brake System Service

1. Check the oil level in the axle and replenish with oil as required.

2. Bleed the brakes.

3. Check brake pressure.

4. Check brake operation.

2.12.6 After Transmission Service or Replacement

1. Check transmission oil level and fill to level with oil as required. (Refer to information on transmission lubricants.)

2. Replace transmission filter.

3. Check torque on drive shaft yoke retaining bolts. Tighten these M12 bolts to 156 lb/ft (212 Nm).

4. Refer to the ZF 4 WG-98 TS Transmission Repair Manual (ZF part number 5871 139 002, JLG part number 8990418) for servicing the transmission after overhaul or repair.

5. Wear suitable eye protection. When an overhauled or repaired transmission is installed, thoroughly clean the oil cooler lines to and from the transmission.

6. Drain and flush the entire system.

7. Disconnect and clean all transmission lines. When possible, remove transmissions lines from the vehicle for cleaning.

8. Thoroughly clean transmission filter screens and cases, and replace transmission filter elements.

Section 2.6.6, Transmission

for

CAUTION: DO NOT exceed 165 psi

(11,4 bar) when back flushing the oil cooler. Applying too much pressure may damage the oil cooler/radiator.

9. “Back flush” the transmission oil cooler with oil and compressed air until all foreign material is removed. Flushing in direction of normal oil flow does not adequately clean the cooler. If needed, remove the transmission oil cooler assembly from the vehicle. DO NOT use flushing compounds for cleaning purposes.

10. Reassemble all components and fill the transmission with clean, fresh oil through the dipstick tube opening until oil comes up to the FULL mark on the transmission dipstick.

11. Run engine for two minutes at idle to help prime the torque converter and transmission lines.

2.12.5 After Fuel System Service

1. Drain and flush fuel tank; if it was contaminated.

2. Bleed fuel system.

3. Fill fuel tank with fresh, clean fuel, as required.

2.26

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

12. Recheck the level of fluid in the transmission with the engine running at idle.

13. Add oil as necessary to bring the fluid level up to the FULL mark on the transmission dipstick. Install the oil dipstick. Recheck the oil level when it reaches operating temperature (180-200° F or 83-94° C).

14. Recheck all drain plugs, lines, connections, etc., for leaks and tighten where necessary.

2.12.7 After Tire and Wheel Service

1. Check air pressure.

2. Be sure the lockwashers are properly positioned under each wheel nut.

3. Check wheel nut torque. Tighten to 430-470 lb/ft (583-637 Nm).

2.12.8 After Engine Service

Consult the qualified service agent (manufacturer’s representative and/or service manual) for proper procedures before engine startup.

2.12.9 After Boom Service

1. Check wear pads.

2. Check chain tension adjustment.

3. Apply grease at all lubrication points (grease fittings).

4. Check for proper operation by operating all boom functions through their full range of motion several times.

2.12.10 After Axle Service

1. Check fluid levels.

2. Check torque on drive shaft flange yoke retaining bolts. Tighten these M12 bolts to 156 lb/ft (212 Nm).

3. Be sure the lockwashers are properly positioned under each wheel nut.

4. Check wheel nut torque. Tighten to 430-470 lb/ft (583-637 Nm).

5. Check toe-in if required.

6. Apply grease at all lubrication points (grease fittings).

7. Refer to the axle manufacturer’s maintenance manual for further information.

Model MMV Rev. 12/04

2.27

General Information, Specifications and Maintenance

2.13 MAINTENANCE INSTRUCTIONS

WARNING: DO NOT service the

vehicle without following all safety precautions as outlined in the “Safety Practices” section of this manual. Failure to follow the safety practices may result in death or serious injury.

WARNING: DO NOT perform ser-

vice or maintenance on the vehicle with the engine running. Contact with moving parts can cause death or serious injury.

This section contains a routine equipment checklist and a maintenance schedule and checklist with references to pertinent procedures and instructions. To help prevent problems before they occur, follow the maintenance schedule.

2.13.1 Maintenance Schedule and Checklist

a. 10 Hour Intervals

At ten-hour intervals, perform the following:

Drain

Fuel/Water

Separator

• Drain the fuel/water separator (refer to

2.13.7, Engine Fuel System

• Check the engine coolant level (refer to

2.13.4, Engine Cooling System

• Check the engine oil level (refer to

2.13.5, Engine Oil and Filter

Inspect

Wear Pads

Check Engine

Coolant Level

Emergency Tire Inflation Tank

Check Engine

Oil Level

Drain Water From

Check

Hydraulic

Oil Level

Check

Transmission

Oil Level

Inspect and/or Clean Air Compressor Intake Filter

Check

Tire

Pressure

Section

MM3211

• Check the hydraulic reservoir oil level (refer to

Section 2.13.9, Hydraulic System Oil and Filter

• Check the transmission oil level (refer to

2.13.10, Transmission Oil and Filter

• Check the air pressure in the tires (refer to

tion 2.13.15, Wheels and Tires

• Check boom wear pad thickness (refer to

2.13.19, Boom Wear Pad Maintenance

Section

Sec-

Section

• Drain water from emergency tire inflation tank (refer to

tion System

Section 2.13.16, Emergency Tire Infla-

• Inspect and/or clean air compressor intake filter (refer to

tion System

Section 2.13.16, Emergency Tire Infla-

OS1171

Note: Lubrication (1) and maintenance (2) chart decals are located inside the engine compartment cover (3). These decals contain a general maintenance schedule that should be followed to maintain the vehicle in good operating condition. The same schedule information is presented in this manual, except that it contains a more detailed account of how to perform these specific maintenance operations.

2.28

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

b. At First 50 Hours of Use

Change Engine

Oil and Filter

Change Axle Oil

Change

Transmission

Filter

Wheel End Oil

Change

Hydraulic

Filter

Change Transfer Case Oil

430-470 (583-637)

/ F

(

)

Check

Wheel Lug Nut Torque

MM3200

When the vehicle completes its first 50 hours of use, perform the following:

• Change the engine oil and filter (refer to

2.13.5, Engine Oil and Filter

• Change the transmission filter (refer to

2.13.10, Transmission Oil and Filter

• Change the hydraulic filter (refer to

2.13.9, Hydraulic System Oil and Filter

• Change the transfer case oil (refer to

2.13.14, Transfer Case Oil

• Change the axle oil (refer to

Axle Oil

Section 2.13.11,

• Change the wheel end oil (refer to

2.13.13, Wheel End Oil

• Check the wheel lug nut torque (refer to

2.13.15, Wheels and Tires

Section

• Check the wheel end oil level (refer to

2.13.13, Wheel End Oil

• Inspect Extend Chains (refer to

Boom Chain Tension & Adjustment

Section 2.13.21,

• Apply multi-purpose grease at all lubrication points. Lubricate the following components via the grease fittings with good grade of a multipurpose, lithium-based grease every 250 hours (remove all excess grease):

2/ 2/

Section

c. 250 Hour Intervals

250

Change

Engine Oil & Filter

Check

Wheel EndOil Level

Check

Transfer Case Oil Level

Lubricate

Fittings

Check

Axle Oil Level

Extend Chains

At 250 hour intervals, perform the following:

• Change the engine oil and filter (refer to

2.13.5, Engine Oil and Filter

• Check the transfer case oil level (refer to

2.13.14, Transfer Case Oil

• Check the axle oil level (refer to

Axle Oil

Model MMV Rev. 12/04

Section 2.13.11,

Inspect

MM3220

Section

B B

MM4150

A. Hydraulic cylinder pins ............................ 14 points

B. Powertrain slip joints & axle U-joints....... 11 points

C. Boom pivot pin .......................................... 4 points

D. Quick attach pivot pin................................ 2 points

E. Axle pivot pins........................................... 4 points

F. Chain sheave............................................. 2 points

Note: Shorten the lubrication interval on all lubrication

points when operating under severe conditions.

2.29

General Information, Specifications and Maintenance

d. 500 Hour Intervals

500

Change

Fuel

Filter

Section 2.13.2, Air

Section 2.13.7,

Change Axle Oil

Check

Air Intake

Fan

System

Belt

Section 2.13.11,

Section

Section 2.13.12,

Section 2.13.8,

Section 2.13.2,

Section 2.13.22,

Section

Change

Air

Filter

At 500 hour intervals, perform the following:

• Change the air filter (refer to

Cleaner

• Change the fuel filter (refer to

Engine Fuel System

e. 1,000 Hour Intervals

0001

Check

Boom Chain

Tension

Change

Transfer Case Oil

Change Transmission Oil and Filter

Check Brake

Disk Wear

Hydraulic

Oil and Filter

At 1,000 hour intervals, perform the following:

• Check boom chain tension (refer to

2.13.21, Boom Chain Tension & Adjustment

• Change the transmission oil and filter (refer to

Section 2.13.10, Transmission Oil and Filter

• Change the hydraulic oil and filter (refer to

2.13.9, Hydraulic System Oil and Filter

• Change the axle oil (refer to

Axle Oil

• Change the wheel end oil (refer to

2.13.13, Wheel End Oil

• Change the transfer case oil (refer to

2.13.14, Transfer Case Oil

• Check brake disc wear (refer to

Brake Disc Wear Check

• Check the fan belt (refer to

Engine Fan Belt & Air Conditioner Compressor Belt

• Check air intake system (refer to

Air Cleaner

• Lubricate Boom Chains (refer to

Chain Lubrication

MT00701

Change

Wheel End Oil

Lubricate

Boom Chain

MM4160

Section

f. 2,000 Hour Intervals

0002

Change

Engine

Coolant

MS1380

At 2,000 hour intervals, perform the following:

• Change the engine coolant (refer to

2.13.4, Engine Cooling System

Section

2.13.2 Air Cleaner

a. Engine Air Restriction Warning Indicator

The operator’s display panel includes an indicator light (1) that illuminates to alert the operator when restricted air flow to the engine is sensed. This indicates that the air filter needs servicing. NEVER operate the vehicle without the air cleaner assembly and both filters in place.

b. Air Cleaner Element: Change

OM07312

500

MS21802 OS0790

As indicated by the air cleaner restriction indicator, and/or every 500 hours, change the air filter element.

2.30

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

Outer Primary Element

All air cleaner manufacturers agree that attempting to clean or wash an element increases the chance for element damage. It is highly recommended that you consider the value of cleaning an element against the risks that could lead to engine damage. Adopt the policy that all elements should be replaced with new

and not cleaned.

Inner Safety Element

An inner safety element should NEVER be washed or reused. ALWAYS

Replace safety elements after every third primary element change. DO NOT remove a safety element until the inside of the air cleaner canister is thoroughly cleaned. This will help prevent dirt that could damage the engine from entering the induction manifold.

install a new element.

CAUTION: NEVER run the engine

with only the safety element installed. Severe engine damage will result from dust entering the engine.

4. If replacing the inner element (8) at this time, carefully slide the element out. Always discard this element and replace with a new element.

5. Slide the new primary element over the inner element making sure the sealing edge is flush with the base of the air cleaner.

IMPORTANT: DO NOT apply any type of petroleum product to the sealing surface of the filter in an attempt to get a more positive seal. This will cause sealing surface damage and allow dirt to by-pass the filter. Use liquid dishwashing soap (Ivory, Dawn, etc.) on the seal of the filter only.

6. Position the canister cover (3) in place, turn clockwise to lock into position and secure in place by pushing the air cleaner cover lock (2) all the way in.

OM0980

To change elements:

1. Pull the air cleaner cover lock (2) out, turn the air cleaner cover (3) counter-clockwise and remove the cover from the air cleaner canister (4).

2. Remove the primary element (5). Inspect the element for damage. Damaged elements should never be reused.

3. Thoroughly clean the interior of the air filter canister (6) and vacuator valve (7).

c. Air Intake System-Inspection

OM0990

0001

MS21902

Inspect the intake piping for cracked hoses, loose clamps, or punctures that can allow dirt or debris to enter the combustion chamber. If dirt or debris is allowed to enter the combustion chamber, it can severely damage the engine. If necessary, tighten or replace parts to help prevent air intake system leakage.

OT0880

Model MMV Rev. 12/04

2.31

General Information, Specifications and Maintenance

2.13.3 Closed Cab Air Filters

The closed cab has two air filters, the recirculation air filter and the fresh air intake filter. Both of these filters require periodic inspection and maintenance.

Recirculation Air Filter

Periodically remove two truss-head bolts (1), vent cover (2) the recirculation air filter (3) located directly below the seat. Inspect the filter. Gently hand wash with water, a mild detergent may also be used if the filter is saturated with dirt.

Fresh Air Intake Filter

Periodically remove the cab rear panel and inspect the fresh air intake filter (7). The filter must be cleaned sometimes as often as twice a day, depending on the operating environment. This is done by removing the filter and shaking it. The filter can be gently hand washed with water. A mild detergent may also be used if the filter is saturated with dirt. When re-installing the filter make sure the filter is held in place with both filter latches (4 and 6). The filter will clean outside air when pressurizing the cab. The filter should be replaced at 250 hour intervals under normal operating conditions and at 50 hour intervals under extreme operating conditions.

Note: Correctly position the filter so the air flow (5) is directed into the cab.

OS1791

OS1810

4. Filter latch

5. Direction of air flow

6. Filter latch

7. Fresh air intake filter

2.32

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.13.4 Engine Cooling System

a. Engine Coolant Level Check (10 Hour Intervals)

MS21402

1. Level the vehicle, ground the attachment, place the travel select lever in the [N] NEUTRAL position, place the neutral lock lever in the [N] NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF.

2. Unlatch and open the engine cover.

3. Check the coolant level in the overflow bottle (8). When the coolant is hot, the bottle should be half to three-quarters full. When the coolant is cool, the bottle should be one-quarter to half full. Add coolant (use a 50/50 mixture of ethylene glycol and water) as required through the overflow bottle.

OS0800

b. Drain and Flush the Radiator

2000

MS3000

2. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the vehicle should not be operated. (Refer to

1.5, Accident Prevention Tag Usage

WARNING: DO NOT attempt this

procedure when the engine is hot. Wait for the engine, muffler, and tailpipes to cool down before proceeding. Failure to do so could result in severe burns.

OS0810

Section

3. Unlatch and open the engine cover. Allow the engine to cool before proceeding. Draining and flushing the

cooling system while the engine is hot can cause cracks in the engine block.

WARNING: NEVER remove the

radiator cap while the engine is hot. The cooling system is under pressure. Hot coolant can cause severe burns or eye injury. Wear protective clothing and safety glasses.

OM1630

Model MMV Rev. 12/04

2.33

General Information, Specifications and Maintenance

4. Slowly turn the radiator cap (1), located in the upper radiator hose, to the first stop and allow any pressure to escape. Remove the radiator cap.

5. Place a funnel (2) at the base of the radiator to channel the drained coolant into a container. Unscrew the radiator drain plug (3) and allow the coolant to drain into the funnel.

6. Detach the hose (4) from the fitting (5) on the neck of the radiator fill tube and drain any coolant from the overflow bottle into the funnel.

7. Flush the radiator with clean water, and flush drain again.

OM1640

8. Remove the engine block drain plug (6) and drain any coolant from the engine block. Replace the engine block plug.

9. Transfer the coolant to a container with a cover and label the container “Used Anti-freeze.” Dispose of the used coolant at an approved recycling facility.

10. Reconnect the hose (4) to the fitting on (5) the neck of the radiator fill tube. Close the radiator drain plug or petcock.

OM1300

11. Open the petcock (7) on the turbo aftercooler.

12. Fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace the radiator cap. Add coolant to the overflow bottle until the bottle is half to three-quarters full. This “overfilling” will compensate for any air in the cooling system.

13. Close the petcock (7) on the turbo aftercooler.

14. Clean dirt and debris from the radiator core.

15. Start and run the engine until normal engine operating temperature is reached, then turn the engine OFF. Check for leaks while the engine is cooling.

16. After engine has cooled for several minutes, open the petcock (7) on the turbo aftercooler. Allow air in the system to escape. Close the petcock when coolant starts flowing from the petcock. All air is now purged from the aftercooler.

17. Allow the engine to cool. Check the radiator coolant level again and top off as needed with a 50/50 mixture of ethylene glycol and water. Replace the radiator cap.

18. The overflow bottle should be one-quarter to one-half full. If not, fill as necessary with a 50/50 mixture of ethylene glycol and water.

2.34

OT0260

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.13.5 Engine Oil and Filter

a. Engine Oil Recommendations

The use of quality engine oil combined with the appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability. (Refer to the chart below for recommended oil types for various operating conditions).

Recommended Engine Oil/Temperature Range

MIL-PRF-2104G Grade 15W40 (SAE 15W40)

MIL-PRF-2104G

Grade 5W30

(SAE 5W30)

MIL-PRF-2104G Grade 0W30 (SAE 0W30)

-25° F (-32° C)

Engine oil capacity, with filter change, is 13.3 quarts (12,6 liters).

23° F (-5° C)

OM1710

b. Oil Level Check

MS21402 OS0820

2. Open the engine cover.

3. Remove the engine dipstick (8). Check the oil mark on the dipstick. The oil should be within the crosshatched area of the dipstick.

4. Add oil as required. Replace the dipstick.

Full

Add

Model MMV Rev. 12/04

OT0060

2.35

General Information, Specifications and Maintenance

c. Oil and Filter Change

OH26701 MS21702 OS0830

Change the oil and filter after the first 50 hours of vehicle operation, at 250-hour intervals. To change the oil and filter:

1. Operate the engine until it reaches operating temperature (approximately five minutes).

2. Level the vehicle, ground the attachment, place the travel select lever in the [N] NEUTRAL position, place the neutral lock lever in the [N] NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF.

3. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the vehicle should not be operated. (Refer to

Accident Prevention Tag Usage

4. Open the engine cover.

250

Section 1.5,

7. Allow the oil to drain completely into the receptacle. Transfer the oil to a container with a cover and label the container as used motor oil. Dispose of used oil at an approved recycling facility.

8. Remove the oil filter (3) and clean the filter-sealing surface. The oil filter is remotely mounted on a bracket under the frame, in front of the transfer box. Access the filter from under the vehicle.

9. Apply a thin coat of clean engine oil to the new filter mating surface.

10. Install the new oil filter and hand tighten. Use an oil filter wrench or strap to tighten the filter down an additional one-quarter to half turn. DO NOT overtighten.

11. Turn the oil drain petcock lever (2) clockwise and lock into the CLOSED position. The petcock lever is spring loaded and will lock in the CLOSED position.

12. Remove the engine oil fill cap (5) and add oil (refer to the recommended engine oil/temperature range chart on page 2.35 for recommended oil types for various operating conditions). Engine oil capacity with filter change is 13.3 qt (12,6 liters).

13. Reinstall the oil fill cap. Start the engine and allow it to run for several minutes.

14. Shut off the engine. Wait several minutes, and then check the oil level again on the dipstick (4). Add oil as required. DO NOT overfill.

15. Look for oil leaks at the filter and drain plug. Tighten as required.

5. Place an oil drain pan under the engine oil pan drain hose (1). The hose is located under the engine up behind the hydraulic oil reservoir.

6. Lift the petcock lever (2) up and turn counterclockwise to OPEN and drain the oil from the engine oil pan.

2.36

OM1310

OM1740

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.13.7 Engine Fuel System

a. Drain Water from Fuel-Water Separator/Filter

2.13.6 Engine Oil Sample Point

1. Open the engine cover.

2. Locate the oil sample valve (6) on the side of the engine.

3. After oil sample has been taken, close the engine cover.

MM4570

MS21402 OS0851

2. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the vehicle should not be operated. (Refer to

1.5, Accident Prevention Tag Usage

Section

3. Open the engine compartment cover.

4. Position a suitable glass container beneath the fuel filter drain cock (7), located on the underside of the fuel filter (8).

5. Loosen the fuel filter drain cock. Allow the water to drain into the glass container until clear fuel is visible. After draining is complete, tighten the drain cock. Dispose of drainage properly.

6. Close the engine compartment cover.

Model MMV Rev. 12/04

OM1321

MM3240

2.37

General Information, Specifications and Maintenance

b. Change Fuel Filter

500

MS21802 OS0870

Change the fuel filter every 500 hours of engine operation, or at shorter intervals with water evidence of contaminated fuel.

2. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the vehicle should not be operated. (Refer to

1.5, Accident Prevention Tag Usage

3. Open the engine cover. Clean around the fuel-filter head (1).

4. Unscrew the fuel filter and dispose of properly.

5. Clean the filter head gasket surface and replace the o-ring.

6. Fill the new fuel filter (2) with clean No. 2 diesel fuel. Alternate fuels can also be used. They are: JP-5, JP-8 or Jet A-1.

7. Lubricate the o-ring seal (3) with clean No. 2 diesel fuel. Alternate fuels can also be used. They are: JP-5, JP-8 or Jet A-1.

8. Install the fuel-filled filter and tighten by hand. DO NOT over-tighten.

Section

c. In-line Fuel Strainer

500

MS21802 OS0870

1. Level the vehicle, ground the attachment, place the travel select lever in the NEUTRAL [N] position, place the neutral lock lever in the [N] NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF. Allow engine to cool.

2. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the vehicle should not be operated. (Refer to

1.5, Accident Prevention Tag Usage

Section

Note: DO NOT over-tighten. DO NOT tighten with

mechanical means (tools, etc.). Mechanical over-tightening may distort the threads or damage the o-ring seal.

9. Close the engine cover.

Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by changing the fuel filter element will be vented automatically as long as the element was filled with fuel prior to installation.

2.38

3. Open the engine cover.

4. The in-line fuel strainer (4) is located down line from the engine lift pump (5). Loosen the two hose clamps (6) securing the strainer in place.

Model MMV Rev. 12/04

MM3240

General Information, Specifications and Maintenance

5. Remove and properly dispose of the old strainer.

6. Install the new strainer with the arrow pointing toward the lift pump.

7. Assemble the hoses to the strainer and tighten the hose clamps.

8. Remove air from the fuel system. (Refer to

2.13.7, d. Venting Air from the Fuel System

9. Close the engine cover.

d. Venting Air from the Fuel System

Section

WARNING: DO NOT vent air from

the fuel system of a hot engine. Allow the engine to cool before attempting to purge air from the fuel system. Failure to do so could create a fire hazard.

Air must be vented from the fuel system whenever any component between the fuel tank and the injection pump has been disconnected, or when the system has been emptied, or has run out of fuel.

IMPORTANT: DO NOT attempt to start the engine until the injection pump has been filled and primed with fuel. Serious damage to the lift pump will result due to lack of proper lubrication.

1. To vent the low pressure lines and fuel filter, open the vent screw (7), located on the filter head.

2. Operate the hand plunger (8) on the lift pump (5) until fuel flowing from the fitting is free of air.

3. Tighten the vent screw and torque to 7 lb/ft (9 Nm).

The process of venting the high-pressure fuel lines (9) involves energizing the starter motor, which rotates the crankshaft, which, in turn, operates the fuel pump to purge air from the high-pressure fuel lines.

WARNING: Diesel fuel under pres-

sure can penetrate the skin and cause serious personal injury. Slowly loosen fittings and allow release of residual pressure before removing any fuel line.

4. Loosen one high-pressure line fitting (10) at the injector (11). Operate the starter motor for 15 seconds. Wait two minutes. Operate the starter motor again for 15 seconds. Repeat this process until fuel, free of air, comes out of the injector fitting.

OS0990

5. Tighten the fitting to 22 lb/ft (30 Nm). Repeat this procedure for each fitting until the engine runs smoothly. With the engine running, visually check for leaks. Turn the ignition switch OFF.

CAUTION: When cranking the

engine with the starter motor to vent air from the fuel system, DO NOT energize the starter solenoid or crank the engine for more than 15 seconds at a time. Wait two minutes between each 15-second cranking interval.

Model MMV Rev. 12/04

2.39

General Information, Specifications and Maintenance

2.13.8 Engine Fan Belt & Air Conditioner Compressor Belt

0001

MS21902 OS0880

a. Engine Fan Belt

1. Ground the attachment, place the travel select lever in the [N] NEUTRAL position, place the neutral lock lever in the [N] NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF. Allow engine to cool.

2. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the vehicle should not be operated. (Refer to

1.5, Accident Prevention Tag Usage

3. Open the engine cover.

4. Inspect the engine fan belt. Replace if cracked or frayed.

5. This engine is equipped with an automatic belt tensioner (1). Insert a 1/2" drive ratchet into the square hole (2) in the tensioner, and rotate the ratchet up to remove tension from the belt. Remove the fan belt (3).

6. Inspect the fan belt and tensioner bearing. Inspect the fan belt. Replace if cracked or frayed. Spin the bearing, and check for resistance or rough spots in bearing travel.

7. Spin the fan and check for wobble or excessive play. Maximum play should be 0.006 inch (0,15 mm).

8. To install the fan belt, position the belt over the alternator (4), fan (5) and crankshaft (6) pulleys. While holding the tensioner up, slide the belt over the water pump pulley (7).

9. Close the engine compartment cover.

Section

b. Air Conditioner Compressor Belt

2. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the vehicle should not be operated. (Refer to

1.5, Accident Prevention Tag Usage

3. Open the engine cover.

4. Inspect the air conditioner compressor belt (8). Replace if cracked or frayed.

5. Check the tension of the compressor belt (8) midway between the fan pulley (9) and the compressor pulley (10). The belt deflection should be 3/16" (4,8 mm) with an applied force of 5-1/2 lb (2,5 kg).

6. Adjust the tension on the belt by loosening the bolt (11) on the belt tensioning pulley (12). Reposition the pulley and securely tighten the bolt.

7. Recheck the tension and readjust if needed.

8. Close the engine compartment cover.

Section

MT1840

2.40

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.13.9 Hydraulic System Oil and Filter

a. Hydraulic Oil Level Check

MM4570

Recommended Hydraulic Oil/Temperature Range

MIL-PRF-2104G Grade 10

(Automatic Transmission Fluid)

DEXRON lll

14° F (-10° C)

125° F (50° C)

OM1700

5. DO NOT add oil through the hydraulic oil tank breather (14) located beside the suction hose fitting.

MS21402 OS0660

1. Level the vehicle, ground the attachment, place the travel select lever in the [N] NEUTRAL position, place the neutral lock lever in the [N] NEUTRAL LOCK position, and engage the parking brake switch.

2. Fully retract all hydraulic cylinders and shut the engine OFF.

3. Allow the hydraulic oil to cool.

4. Open the engine cover. Locate the hydraulic oil sight glass (13) along the vertical wall of the hydraulic oil tank. Check the level of the hydraulic oil in the tank. The oil level should be in the upper 2/3 to 3/4 of the sight glass when oil is cold and all cylinders retracted. If hydraulic oil is not visible, remove the hydraulic oil fill cap (15) and add hydraulic oil (see the following chart for oil recommendations) until the level of the oil is visible in the upper 2/3 to 3/4 of the sight glass. DO NOT overfill.

6. Reinstall the hydraulic oil fill cap (15). Close the engine cover.

OM1071

OT06602

Model MMV Rev. 12/04

2.41

General Information, Specifications and Maintenance

b. Hydraulic Oil and Hydraulic Oil Filter Change

OH26701

OT0840

0001

MS21902 OS0840

Change the hydraulic oil filter after the first 50 hours of engine operation, and every 1,000 hours of operation thereafter.

Also, the hydraulic draulic oil filter restriction warning indicator light (1) on the operator’s instrument panel begins to flicker ON and OFF at high idle.

filter must be changed anytime the hy-

3. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the vehicle should not be operated. (Refer to

1.5, Accident Prevention Tag Usage

4. Open the engine cover. Allow the hydraulic oil to cool.

5. Clean around the hydraulic oil filter head (2). Loosen, but DO NOT remove, the nuts that secure the hydraulic oil filter head to the hydraulic oil reservoir (3).

6. Place a suitable container under the hydraulic reservoir drain plug. The container must be large enough to hold 30 gallons (113 liters) of hydraulic oil.

7. To facilitate removal of the hydraulic oil filter head and filter, the hydraulic oil return line may need to be swiveled out of the way, and the indicator wiring unplugged. DO NOT crimp the hydraulic oil return line or indicator wiring. Rotate and remove the hydraulic oil filter head; be prepared for a large amount of oil to be displaced.

Section

OM07312

WARNING: DO NOT change the

hydraulic oil, or the hydraulic oil filter with the engine running. Contact with moving parts can cause death or serious injury.

2. Fully retract all hydraulic cylinders and shut the engine OFF.

8. Remove the hydraulic oil filter element (5) and seal (6) from the hydraulic oil filter head (7). Dispose of used filter properly.

9. Clean the filter head sealing surface.

10. Remove the magnetic drain plug (8) and allow the hydraulic oil to drain into the container. Clean loose particles from the magnetic drain plug. Transfer the used hydraulic oil to a container with a cover and label the container as used hydraulic oil. Dispose of used oil at an approved recycling facility.

11. Reinstall the magnetic drain plug into the hydraulic oil reservoir.

12. Reinstall the top seal (6) and fully install a new hydraulic oil filter element onto the hydraulic oil filter head until the filter seats. Slide the filter assembly into the reservoir (9). Secure the filter head by tightening the nuts loosened earlier.

OT06602

2.42

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

13. If the hydraulic oil return line was swiveled out of the way, reposition the line. If the indicator wiring was unplugged, reconnect it.

14. Remove the fill cap (4) and fill with hydraulic oil until the oil level is visible within the lower end of the sight glass (10). Refer to the recommended hydraulic oil/ temperature range chart on page 2.41 for proper oil to use. Reservoir capacity is 28.5 gallons (108 liters). Reinstall the fill cap. DO NOT add oil through the hydraulic oil tank breather (11) located beside the suction hose fitting. Thoroughly clean or wipe up any spilled hydraulic oil.

15. Close the engine compartment cover.

16. Operate all hydraulic functions through their full range of motion several times. Cycle all control modes to help purge air from the hydraulic system.

WARNING: Hydraulic oil leaking

under pressure can penetrate the skin and cause severe personal injury. DO NOT use your hand or any part of your body to check for hydraulic leaks. When checking for hydraulic leaks, wear safety glasses and gloves to help provide protection from spraying hydraulic oil. Use a piece of cardboard or paper to search for leaks.

2.13.10 Transmission Oil and Filter

a. Transmission Oil Level Check

MS21402 OS0890

2. Open the engine compartment cover.

3. Check the transmission oil level with the engine at idle and the oil at normal operating temperature.

4. Remove the transmission dipstick (12). Check the transmission oil level.

OM1610

OM1221

5. As required, add oil (refer to the recommended transmission oil/temperature range chart on page 2.44 for proper oil) to the transmission to bring the level up to the full mark.

6. Close the engine compartment cover.

Model MMV Rev. 12/04

2.43

General Information, Specifications and Maintenance

b. Transmission Oil and Filter Change

OH26701

OT0830

0001

MS21902

2. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the vehicle should not be operated. (Refer to

1.5, Accident Prevention Tag Usage

3. Open the engine compartment cover. Allow the engine and transmission to cool.

4. Place a suitable receptacle under the transmission drain plug (1). Remove the drain plug and allow the oil to drain into the receptacle. Transfer the used oil into a suitable covered container and label the container as used transmission oil. Dispose of used oil at an approved recycling facility.

Note: ALWAYS replace used o-rings with new o-rings to ensure proper sealing.

5. Clean and reinstall the transmission drain plug, using a new o-ring, into the transmission housing. Torque the drain plug to 26 lb/ft (35 Nm).

6. Remove the transmission oil filter (2) and dispose of properly. Clean the mating surface where the filter mounts.

7. Apply a thin film of clean oil to the new filter gasket. Install the new filter.

OS0950

Section

8. Transmission oil may be added through the dipstick tube (3). Remove the dipstick and fill with approximately 12 quarts (11,4 liters) of oil (see the following chart for oil recommendations). Check the level by taking intermittent dipstick readings as outlined in Transmission Oil Level Check. DO NOT overfill. Reinstall the dipstick when finished.

Recommended Transmission Oil/Temperature

Range

MIL-PRF-2104G Grade 15W40

MIL-PRF-2104G

Grade 10W30

(Universal Tractor Fluid*)

DEXRON lll

(Automatic

Transmission Fluid)

14° F (-10° C)

*John Deere (JDM J20C Hy-Gard) *Ford/New Holland ESN-M2C134-D (Hydraulic Oil 134) *Massey Ferguson M-1141 (Permatran lll) *Chevron 1000 THF

125° F (50° C)

OM1690

9. Close the engine compartment cover.

OT04702

2.44

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.13.11 Axle Oil

a. Axle Oil Level Check

250

MS21702 OT0460

2. Clean the area around the axle fill (4), and level plugs (5) then remove the plugs from the axle housing.

3. Add oil (see the following chart for oil recommendations) to bring the oil level up, even with the bottom of the level plug holes.

OT02702

Note: ALWAYS replace used o-rings with new o-rings to

ensure proper sealing.

4. Reinstall the axle fill (4) and level (5) plugs into the axle housing using new o-rings. Torque the axle fill and level plugs to 96 lb/ft (130 Nm).

Recommended Axle Oil/Temperature Range

MIL-PRF-2104G Grade 15W40

MIL-PRF-2104G Grade 10W30

(Universal Tractor Fluid*)

100° F (38° C)

*John Deere (JDM J20C Hy-Gard) *Ford/New Holland ESN-M2C134-D (Hydraulic Oil 134) *Massey Ferguson M-1141 (Permatran lll) *Chevron 1000 THF

OM1680

b. Axle Oil Change

OH26701

0001

MS21902 OT0440

2. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the vehicle should not be operated. (Refer to

1.5, Accident Prevention Tag Usage

Section

3. Clean the area around both the axle fill (4), axle level plugs (5) and the axle drain plug (6).

4. Place a suitable receptacle under the axle drain plug (6). Remove the plug from the axle housing and allow the axle oil to drain completely.

5. Transfer the oil to a container with a cover and label the container as used axle oil. Dispose of used oil at an approved recycling facility.

6. Remove the axle fill/level plug (4) from the axle housing.

Model MMV Rev. 12/04

2.45

General Information, Specifications and Maintenance

7. Check brake disc wear. (Refer to

Brake Disc Wear Check

Note: ALWAYS replace used o-rings with new o-rings to ensure proper sealing.

8. Clean and reinstall the drain plug (1) using a new oring. Torque the drain plug to 96 lb/ft (130 Nm).

9. Fill the axle with oil. Refer to the recommended axle oil/temperature range chart on page 2.45 for proper oil to use. Filling is accomplished through the axle fill hole (2). Fill axle slowly, the oil has to run across the differential. Allow time for the oil to run across the differential. Fill until the axle oil level is even with the level plug holes (3). The axle capacity is 10.5 quarts (10,0 liters).

10. Reinstall the axle fill and level plugs (2 and 3) into the axle housing using new o-rings. Torque the level plugs to 96 lb/ft (130 Nm).

Section 2.13.12,

2.13.12 Brake Disc Wear Check

0001

MS21902 MT2830

Check the brake discs for wear, every 1,000 hours of engine operation, or yearly.

If the brake discs require service due to wear, detailed axle service instructions (covering axle, brakes and wheel-end safety, repair, disassembly, reassembly, adjustment and troubleshooting information) are provided in the ZF Axle Repair Manuals, Model MS-T 3060, front axle with parking brake (ZF part # 5871 560 002, JLG part #

8990430) or Model MS-T 3045, rear axle without parking brake (ZF part # 5871 550 002, JLG part # 8990419).

The axle should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.

a. Front Axle

WARNING: BLOCK ALL FOUR

WHEELS. Failure to do so could result in death or serious injury from vehicle roll-away.

1. Block all four wheels to help prevent the vehicle

OT02702

from moving after the parking brake is disabled.

2. Turn the ignition switch to the ON position (with the engine not running), release the parking brake switch, and have the operator seated in the seat.

3. Open the engine compartment cover. Allow the hydraulic oil to cool.

4. Locate the emergency towing pressurizing valve (4) located under the radiator on the mounting bracket.

2.46

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

5. Use the handle (5) on the emergency towing valve to pump pressure into the system. Watch the pressure gauge (6) while pumping pressure into the park brake system. DO NOT exceed 650 psi (45 bar).

CAUTION: DO NOT exceed 650 psi

(45 bar) when pressurizing the park brake. Applying too much pressure may damage the brake seals.

OM1051

6. Working through the level plug hole (7), carefully use a screwdriver to spread the brake discs apart.

IMPORTANT: DO NOT damage the surfaces of the brake discs when spreading the brake discs.

MT2840

9. If the brake wear is within specifications; continue the axle oil change procedure at Step 8 (refer to

Section 2.13.11, b. Axle Oil Change

b. Rear Axle

IMPORTANT: DO NOT damage the surfaces of the

brake discs when spreading the brake discs.

1. Working through the level plug hole (7), carefully use a screwdriver to spread the brake discs apart.

2. Using a feeler gauge, check the gap (8) between the brake discs. If the gap is greater than .167" (4,25 mm), replace the brake discs.

Note: If the brake discs are worn beyond .167" (4,25 mm), the brake disc must be replaced on both sides of the axle at the same time.

MT2850

7. Using a feeler gauge, check the gap (8) between the brake discs. If the gap is greater than .26" (6,75 mm), replace the brake discs.

Note: If the brake discs are worn beyond .26" (6,75 mm), the brake disc must be replaced on both sides of the axle at the same time.

8. Repeat Steps 6-7 for the other side of the axle.

Model MMV Rev. 12/04

3. Repeat Steps 1 and 2 for the other side of the axle.

4. If the brake wear is within specifications; continue the Axle Oil Change procedure at Step 8 (refer to

Section 2.13.11, b. Axle Oil Change

2.47

General Information, Specifications and Maintenance

2.13.13 Wheel End Oil

WARNING: DO NOT perform ser-

vice or maintenance on this vehicle with the engine running. Contact with moving parts can cause death or serious injury.

a. Wheel End Oil Level Check

250

MS21702 OT0430

1. With the vehicle on level ground, move forward or backward enough to ensure that the lower edge of the wheel end fill/drain plug hole (1) is positioned horizontally.

2. Ground the carriage, place the travel select lever in the [N] NEUTRAL position, place the neutral lock lever in the [N] NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF.

3. Clean the area around the wheel end fill/drain plug (1). Slowly remove the plug; pressure may be present. Check the oil level. It should be even with the bottom edge of the hole.

4. As required, add oil (see the following chart for oil recommendations) to bring the level up and even

with the plug hole.

Recommended Wheel End Oil/Temperature

Range

b. Wheel End Oil Change

OH26701

1. Position the vehicle on level ground and move the vehicle forward or backward to place the wheel end fill/drain plug (2) in the six o’clock position.

0001

MS21902 OT0450

OT02802

OT02902

MIL-PRF-2104G Grade 15W40

MIL-PRF-2104G Grade 10W30

(Universal Tractor Fluid*)

100° F (38° C)

*John Deere (JDM J20C Hy-Gard) *Ford/New Holland ESN-M2C134-D (Hydraulic Oil 134) *Massey Ferguson M-1141 (Permatran lll) *Chevron 1000 THF

OM1680

Note: ALWAYS replace used o-rings with new o-rings to ensure proper sealing.

5. Clean and reinstall the wheel end fill/drain plug (1) using new o-rings. Torque the plug to 96 lb/ft (130 Nm).

2.48

3. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the vehicle should not be operated. (Refer to

1.5, Accident Prevention Tag Usage

4. Clean the area around the wheel end fill/drain plug (2). Slowly loosen the plug. Hold a receptacle under the wheel end and remove the plug from the wheel end.

5. Allow the oil to drain completely into the receptacle. Transfer the oil to a container with a cover and label the container as used oil. Dispose of used oil at an approved recycling facility.

6. Reposition the vehicle so the oil level line is placed horizontally (1).

Model MMV Rev. 12/04

Section

General Information, Specifications and Maintenance

7. Fill the wheel end with oil. Refer to the recommended wheel end oil/temperature range on page 2.48 for proper oil to use. The wheel end is full when the oil is level with the bottom of the plug hole. Wheel end oil capacity is approximately 1.3 quarts (1,2 liters).

Note: ALWAYS replace used o-rings with new o-rings to ensure proper sealing.

8. Clean and reinstall the wheel end fill/drain plug (1) using a new o-ring. Torque the plug to 96 lb/ft (130 Nm).

2.13.14 Transfer Case Oil

a. Transfer Case Oil Level Check

b. Transfer Case Oil Change

OT0300

250

MS21702

1. Level the vehicle, ground the carriage, place the travel select lever in the [N] NEUTRAL position, place the neutral lock lever in the [N] NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF.

2. Clean the area around the transfer case oil fill/level plug (3).

3. Remove the oil fill/level plug (3) from the transfer case and check the oil level.

4. Add oil ( see the following chart for oil recommendations) as required through the oil fill/ level hole. Bring the oil level up and even with the oil fill/level plug hole.

5. Clean and reinstall the oil fill/level plug (3). Torque the plug to 52 lb/ft (70 Nm).

Recommended Transfer Case Oil/Temperature

Range

MIL-PRF-2104G Grade 15W40

MIL-PRF-2104G Grade 10W30

(Universal Tractor Fluid*)

100° F (38° C)

*John Deere (JDM J20C Hy-Gard) *Ford/New Holland ESN-M2C134-D (Hydraulic Oil 134) *Massey Ferguson M-1141 (Permatran lll) *Chevron 1000 THF

OT0420

OM1680

OH26701

0001

MS21902

OT0410

2. Place an Accident Prevention Tag on both the ignition switch and steering wheel, stating that the vehicle should not be operated. (Refer to

1.5, Accident Prevention Tag Usage

Section

3. Clean the area around the transfer case oil fill/level plug (3) and oil drain plug (4).

4. Place a receptacle beneath the transfer case drain plug.

5. Remove the drain plug (4) from the transfer case.

6. Allow the oil to drain completely into the receptacle. Transfer the oil into a container with a cover and label as used oil. Dispose of used oil at an approved recycling facility.

7. Clean and reinstall the transfer case drain plug (4). Torque the plug to 52 lb/ft (70 Nm).

8. Remove the oil fill/level plug (3).

9. Fill the transfer case with oil. Refer to the recommended transfer case oil/temperature range on this page for proper oil to use. The transfer case is full when oil is level with the bottom of the oil fill/ level plug hole. Total transfer case oil capacity is 1.5 qt (1,4 liters).

10. Replace the oil fill/level plug (3). Torque the plug to 52 lb/ft (70 Nm). Wipe up any spilled oil.

Model MMV Rev. 12/04

2.49

General Information, Specifications and Maintenance

2.13.15 Wheels and Tires

a. Tire Pressure Check

MS21402 OS0900

DANGER: LOW TIRE PRESSURE

can result in vehicle tipover. MAINTAIN proper tire pressure at all times.

Check all four tires:

1. Remove the valve stem cap.

2. Check tire pressure using a premium-quality gauge. Proper inflation pressure cannot be determined visually. Pressure should be: 87 psi (600 kPa).

3. Add air as required. DO NOT overinflate.

4. Replace the valve stem cap.

b. Wheel Lug Nut Torque Check

430-470 (583-637)

/FT (N

)

OH26702

OM14002

1. Wire brush the area around the lugs if necessary. Foreign material such as dirt, concrete, mud, etc. can prevent an accurate torque reading. There are separate lockwashers (1) under the lug nuts (2). Be sure the lockwashers are installed under each lug nut.

2. Use the torque sequence diagram (A thru K), to alternately check the torque of each of the ten lug nuts. The recommended torque is 430-470 lb/ft (583-637 Nm).

c. Replacing Tires

WARNING: Mis-matched tire sizes

and PLY ratings may compromise vehicle stability and may result in vehicle tipover.

IMPORTANT: The specified size and ply rating for this vehicle is 15.5R25, L-2, 2 Star. Make sure any replacement tire is of the same size and ply rating. DO NOT use lower PLY rated tires on this vehicle.

OM1620

2.13.16 Emergency Tire Inflation System

a. Inspect Air Compressor Intake Filter

MS21402

Note: Shorten the maintenance interval if operating in extremely dusty conditions.

1. Place the vehicle on level ground, ground the attachment, level the vehicle, place the travel select lever in (N) NEUTRAL, move the neutral lock lever to the (N) NEUTRAL LOCK position, engage the parking brake switch and shut off the engine.

OM1580

2.50

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2. Unlatch and open the engine hood.

3. Locate the air compressor intake filter (3) located on the air compressor (4).

4. Visually inspect the air filter. If the filter appears extremely dirty, the filter element requires cleaning and re-oiling and/or replacement.

OM1321

b. Air Intake Filter Assembly Cleaning

Note: The air intake filter assembly must be replaced

after every 25 cleanings or if damaged.

To clean and recharge the filter you will need a filter cleaner/recharger kit. The kit can be ordered by calling JLG at (717) 458-5161 domestically or (877) 554-5438 internationally. This kit contains a 12 oz bottle of filter cleaner and a 6.5 oz spray can of oil.

1. Clean the area around the base of the intake filter assembly where it attaches to the air compressor.

2. Loosen the clamp (5) holding the intake filter assembly (3) to the air compressor and remove the filter assembly from the barbed fitting. Save the clamp for reassembly. If you are replacing the intake filter assembly, the clamp can be discarded.

3. Tap the filter assembly to dislodge any embedded dirt, then gently brush with a soft bristle brush.

4. Spray the outside of the filter assembly with filter cleaner from the filter cleaner/recharger kit. Let the filter soak for 10 minutes.

5. Thoroughly rinse the filter assembly from the inside out using water at low pressure. DO NOT use high pressure water to rinse the filter.

6. Shake off all excess water and allow the filter to dry naturally.

7. After cleaning the filter assembly always re-oil before using. Spray the air filter oil down into each pleat with one pass per pleat. Wait 10 minutes and re-oil any white spots showing.

8. Reassemble the filter (3) onto the barbed fitting (6) and secure in place with the clamp (5). Tighten the clamp securely.

OM1590

c. Air Intake Filter Assembly Replacement

1. Before installing the replacement filter assembly, use the filter oil provided with the new filter and oil the outside of the element. Be sure to cover the entire filter element. Wait 10 minutes and re-oil any white spots showing.

2. Place the new clamp onto the inlet of the filter and assemble to the barbed fitting on the air compressor. Tighten the clamp securely.

Model MMV Rev. 12/04

2.51

General Information, Specifications and Maintenance

d. Drain Water From Emergency Tire Inflation Tank

MS21402 OS0900

Daily, drain the water from the tank. Open the petcock (1) on the bottom of the tank (2) to remove any water that has accumulated inside the tank. Close the petcock after all water has been removed.

e. Tire Inflation

The tire inflation system will enable the tires on this vehicle to be inflated to the proper air pressure without going back to a maintenance area.

1. Place the vehicle on level ground, ground the carriage, level the vehicle, place the travel select lever in (N) NEUTRAL, move the neutral lock lever to the (N) NEUTRAL LOCK position, engage the parking brake switch.

2. Shut the engine OFF.

3. The tire inflation hose (3) is stored inside the seat riser (4). The hose is coiled up and secured in place with velcro strips (5). Remove the hose coil from the seat riser and then remove the velcro straps from around the hose coil.

OM1200

OM12102

2.52

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

4. The air storage tank (2) is located at the front underside of the operators cab.

5. Remove the dust plug (6) from the quick disconnect (7) on the end of the air storage tank.

6. Insert the male end of the tire inflation hose (8) into the quick disconnect (7) on the side of the air storage tank. Push the outside of the quick disconnect back toward the tank, insert the male end into the quick disconnect and release the outside of the quick disconnect to secure the air hose in the disconnect.

OM1030

7. Enter the operators cab and start the engine.

8. Exit the cab and inflate the tire or tires to the proper pressure. The hose is able to reach all four tires.

9. Inflate the tire(s) to: 87 psi (600 kPa).

Check the tire pressure using a good quality tire gauge.

10. Turn the engine OFF before disconnecting the tire inflation hose.

11. Remove the tire inflation hose from the quick disconnect and coil and remount the hose (3) inside the seat riser (4). Be sure to secure the coil of hose to the velcro strips (5) inside the seat riser.

12. Reassemble the dust plug (6) back into the quick disconnect.

Model MMV Rev. 12/04

2.53

General Information, Specifications and Maintenance

2.13.17 Batteries

a. Batteries Inspection, Testing and Service

WARNING: Lead-acid batteries pro-

duce flammable and potentially explosive gases. To avoid personal injury when checking, testing or charging the batteries:

• DO NOT use smoking materials near batteries.

• Keep arcs, sparks and open flames away from batteries.

• Provide adequate ventilation and wear safety glasses.

The batteries are of maintenance-free design. The batteries are filled with electrolyte and charged when shipped with the vehicle. A warning indicator light (1) on the operator’s display panel illuminates when the alternator is no longer able to charge the batteries, or there is a problem in the charging system.

WARNING: Fluid (electrolyte) in

electric storage batteries contains sulfuric acid, a POISON that can cause SEVERE CHEMI- CAL BURNS. Avoid all contact of fluid with eyes, skin or clothing. Use proper protective gear when handling batteries. DO NOT tip a battery beyond a 45° angle in any direction. If contact with battery fluid does occur, follow the First Aid suggestions in the “Battery Fluid (electrolyte) First Aid” box below.

Battery Fluid (Electrolyte) First Aid:

• External Contact — Flush with water.

• Eyes — Flush with water for at least 15 minutes

and g

et medical attention immediately.

• Internal Contact — Drink large quantities of water. Follow with Milk of Magnesia, a beaten egg or vegetable oil. G

DO NOT take fluids that induce vomiting.

IMPORTANT! In case of internal contact, DO NOT

give fluids that would induce vomiting!

et medical attention immediately.

OM07312

To service the batteries:

2. The batteries (2) are located under the main frame one on each side of the frame. Remove the wing nuts (3) from the carriage bolts (4). Remove the battery box covers (5).

3. Wear safety glasses and visually inspect the batteries. Check terminals for corrosion. Check the cable connections to ensure proper tightness. Replace a battery if it has a cracked, melted or damaged case.

OM1020

2.54

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

b. Battery Charging

WARNING: DO NOT charge a fro-

zen battery. A frozen battery could explode and cause death or serious personal injury. Allow the battery to thaw before “slave starting” the vehicle or connecting a battery charger.

Under normal operating conditions, the alternator will keep the batteries charged. The alternator may not be able to charge a battery that has been completely discharged for an extended period of time. Under this condition, a battery charger or a “slave start” is required to recharge the battery.

An attempt to “slave start” the vehicle and let the engine run so the alternator charges the battery can be made before using a battery charger.

c. Slave Starting

WARNING: NEVER slave start the

vehicle directly at the starter motor or starter solenoid. Death or serious personal injury could result from the vehicle lurching forward or backward and running over personnel attempting to slave start the vehicle.

OM1221

4. From the operator’s seat with the seat belt fastened, check that the parking brake switch is engaged. Place the travel select lever in the [N] NEUTRAL position and place the neutral lock lever in the [N] NEUTRAL LOCK position.

5. Turn the ignition switch to the START position (fully clockwise) to crank the engine. Release the ignition when the engine starts. If the engine fails to start on the first try, wait until the engine and starter come to a complete stop before engaging the starter again.

IMPORTANT: DO NOT crank the starting motor continuously for more than 30 seconds. Stop cranking the starter and allow the starter to cool for two minutes before engaging the starter again.

WARNING: To help avoid personal

injury when slave starting with another vehicle, DO NOT allow the vehicles to contact each other. NEVER salve-start a frozen battery. A frozen battery could explode and cause death or serious personal injury. Keep arcs, sparks, lighted smoking materials and open flames away from the batteries. Lead acid batteries produces flammable and potentially explosive gases. Wear safety glasses when working near a batteries.

This vehicle is equipped with a 24 volt, negative ground electrical system. The NATO slave receptacle (6) is located under the engine cover in front of the transmission. Ensure that both disabled and booster vehicles are equipped with a NATO slave receptacle.

1. Connect the slave cable to the booster vehicle slave receptacle.

2. Connect the other end of the slave cable to the disabled vehicle slave receptacle.

3. Run the booster vehicle at a speed just above idle.

WARNING: DO NOT start the

engine unless you are in the seat with the seat belt fastened around you. Death or serious personal injury could result if the belt is not securely fastened.

6. After starting the disabled vehicle, return the booster vehicle to idle.

7. Remove the slave cable from the disabled vehicle first and then from the booster vehicle.

8. Run engine at partial throttle for 30 to 60 seconds before operating the vehicle. Return to idle before engaging the travel or range select levers.

Model MMV Rev. 12/04

2.55

General Information, Specifications and Maintenance

2.13.18 Fuse and Relay Replacement

IMPORTANT: Shut off the engine and follow the battery

disconnect procedure below, before checking the electrical system. Use an ohmmeter to check the resistance of wires and components.

a. Disconnect Batteries

1. Remove engine side battery box cover (1). Remove wing nuts (2) and carriage bolts (3) and set cover and mounting hardware aside for later re-assembly.

2. Disconnect the negative (-) battery cable (4) at the battery negative (-) terminal on the battery in the engine side battery box.

3. Disconnect the negative (-) cable (5) at the bottom of the battery equalizer (6).

MM2911

Fuses and relays help to protect the electrical system. In general, a failed fuse is symptomatic of another electrical problem. Simply replacing the fuse often will not solve the problem. Failed fuses usually are due to simple causes, including loose or corroded connections, or a defective relay.

The main causes of failed fuses include a shorted or grounded wire in the applicable circuit, or a defective electrical component. Visually check the condition of the fuse, wires, connections and components in the involved circuit before replacing a fuse. Check the circuit for shorts, grounding or defective electrical components.

OS10932

MM3230

b. Fuses and Relay (Fuse Block)

The fuses and relays in this vehicle protect the electrical system. The fuse and relay block is mounted under the lower left side of the operators dash panel (7). To gain access, remove the three screws that secure the lower dash panel (8) in place. Refer to the following chart for the locations of fuses and relays within the fuse block (9).

2.56

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

7.5

Before checking a malfunctioning electrical circuit, examine the applicable wiring diagram (refer to

10, Electrical System

) to help identify the components

Section

involved. Problems can often be identified by noting whether other components related to the circuit are functioning properly. When several components or circuits fail at one time, the problem is probably related to a poor ground connection, because several circuits share that same connection.

Refer to

Section 10, Electrical System

for further

information.

12 11 10

13 15

31 17 16

20 21

23 24

No. Amp/Volt Circuit Protected

30 Amp Main

15 Amp Ignition - Preheat

12 2 Amp Hourmeter 13 5 Amp Transmission Gear 14 5 Amp Transmission Direction 15 15 Amp Front Dash Display Panel 16 5 Amp Parking Brake 17 7.5 Amp Joystick Logic Panel 18 30 Amp Power Window 19 3 Amp LMI (Load Moment Indicator) 20 2 Amp Service Brake 21 7.5 Amp Front Wiper/Washer 22 7.5 Amp Left Fork Shift 23 5 Amp Steer Mode 24 7.5 Amp Top Wiper/Washer 25 7.5 Amp Right Fork Shift 26 7.5 Amp Rear Wiper 27 2 Amp Switch Lamps 28 25 Amp Heater 29 40 Amp Neutral Engage Relay 30 12 Volt Door Window Relay 31 12 Volt Closed Cab Accessory Power Relay

25 26

OM10001

c. Fuses, Relays and Circuit Breaker

(Right Side Dash)

There is a separate fuse holder under the right side of the dash containing three fuses. This fuse holder is located in the cab wire harness. To gain access, remove the three screws that secure the lower dash panel (8) in place.

To gain access to the fuses remove the cover (32) from the fuse holder (33).

Refer to the following chart for the size of the fuse and circuit protected.

There are seven relays (37 through 43) mounted to the front of the cab. Refer to the following chart for the voltage rating of each relay and circuit that they control.

No. Amp/Volt Circuit Protected

36 25 Amp Blackout Lights 37 24 Volt Relay - Work Light Power 38 24 Volt Relay - High Beam Power 39 12 Volt Relay - Brake Light 40 12 Volt Relay - Light Power 41 12 Volt Relay - Blackout Ignition 42 12 Volt Relay - Normal Lights Ignition 43 12 Volt Relay - Reverse Signal

7.5 Amp Horn

25 Amp Normal Lights

OM1011

Model MMV Rev. 12/04

2.57

General Information, Specifications and Maintenance

There is one circuit breaker (1) located under the right side of the dash that protects the keyless ignition circuit. It is mounted to the side of the steering column mount just below the flasher.

This circuit breaker will trip if there is a short or grounded wire in the applicable circuit. The circuit breaker will automatically reset once it cools. If the circuit breaker continually trips, check the system for shorts, grounds or defective electrical components.

Under normal operating conditions the circuit breaker should never need replacement. however, if a circuit breaker does not automatically reset, the breaker is defective and replacement is required.

IMPORTANT: The circuit breaker has a long terminal (2) and a short terminal (3). The short terminal is labeled “BAT” and the long terminal is labeled “AUX”. Connect the wires from the battery to the “BAT” terminal and connect the other wires to the “AUX” terminal. If the wires are connected to the wrong terminals and the circuit breaker trips because of a short or grounded wire in the circuit, the contacts in the circuit breaker will melt together and the circuit breaker will not protect the circuit because it cannot open.

AUX

BAT

d. Fuse and Relay (Fuel Shut Off Solenoid)

There is one fuse (4) located under the engine cover. Open the engine cover to gain access to this fuse.

The fuse is a 5 amp fuse which protects the fuel shut off solenoid, located in the engine harness (5). To gain access to the fuse, remove the protective cover (6) from the fuse holder (7).

OM1560

OM1170

There are two fuses (8) located on the bottom side of the equalizer (9). These two fuses are 125 amp fuses and are located on the 12V and 24V positive terminals of the equalizer. These fuses protect the 12V and 24V circuits of the equalizer. You will require a small telescoping mirror to check these two fuses.

If a 125 amp fuse blows, the fuse along with the mounting hardware will have to be replaced as a kit.

Replace a 125 amp fuse as follows:

1. Remove the blown fuse and associated hardware. Discard all items.

2. Insert the new capscrew (10) through the tab (11) on the equalizer (9).

3. Place a flat washer (12) and new fuse (8) onto the capscrew. Position fuse as required to best see through the clear window.

4. Place the positive cable (13) onto the capscrew.

5. Place the nylon shoulder washer (14) onto the capscrew and place against the positive cable with the hub toward the cable.

6. Secure in place with a flat washer (15), lockwasher (16) and hex nut (17). Torque the hex nut to a maximum of 100 lbs/in (11 Nm).

2.58

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

Unlatch and open the rear door. The relay is mounted to the fan shroud.

Remove the protective cover (23) from the fuse holder (24) to gain access to the 15 amp fuse.

OM1570

There is one relay (18) located behind the battery equalizer mounting bracket (19). This relay is a 12 volt relay that controls the fuel shut off solenoid.

OM1351

e. Relay and Fuse

(Air Conditioner Condenser Fan Motor)

OM1660

f. Re-connect Batteries

1. Connect the negative (-) battery cable (25) at the battery negative (-) terminal on the battery in the engine side battery box.

2. Connect the negative (-) battery equalizer cable (26) at the bottom of the battery equalizer (27). Torque the nut to a maximum of 100 lbs/in (11 Nm).

3. Replace engine side battery box cover (28). Use the wing nuts (29) and carriage bolts (30) to secure the cover in place.

There is one relay (20) and one fuse (21) located inside

the rear door (22). The relay is a 12 volt relay that controls the fan on the air conditioner condenser.

The fuse is a 15 amp fuse that protects the fan motor on the air conditioner condenser.

WARNING: DO NOT open the rear

door with the ignition switch in the RUN position. Contact with moving parts can cause death or serious personal injury.

Model MMV Rev. 12/04

MM2911

2.59

General Information, Specifications and Maintenance

2.13.19 Boom Wear Pad Maintenance

MS21402

a. Boom Wear Pad Check

Every 10 hours of engine operation, visually inspect the boom wear pads (1), between the boom sections at the rear and front of the boom for excessive wear.

The average expected service life of boom wear pads varies depending on the particular location of each wear pad within the boom, vehicle use, operating conditions, and the load weight.

If load weights are at, or near, maximum capacity, or if the vehicle is operating in very dirty or dusty conditions, the boom wear pads will wear at a much faster rate.

MT2290

The boom wear pads that are under the most stress from weight of the load will also wear faster than other pads. For example, the lower pads at the front of the boom are under much more stress than the pads attached at the top front or sides of the boom. Consequently, the lower pads will require service more often.

b. Boom Wear Pad Replacement

Each boom wear pad (1), is manufactured with a convenient wear pad indicator (2). This is the angled cut at each end of all boom wear pads. The total thickness of a new boom wear pad is 0.625" (15,9 mm) (3). The angled cut will provide a total wear thickness of 0.25" (6,4 mm) (4). This will leave approximately 0.375" (9,5 mm) of total unused base material.

The pads must NEVER be worn past the angled cut indicator, or the metal pad insert (5) that holds the pads in place will begin to wear into the boom pad sliding surfaces. Pads worn past this point will gouge the boom surfaces. This will result in premature wear of any new boom wear pads installed, eventually requiring, expensive replacement of the boom. Replacement of boom wear pads must be performed when the boom wear pads indicate.

1. Wear pad

2. Angle-cut wear pad indicator

3. 0.625" (15,9 mm)

4. 0.375" (9,5 mm)

5. Metal insert

6. Boom plate

7. Wear pad spacer

OS12302

c. Boom Wear Pad Lubrication

IMPORTANT: The boom has been factory lubricated for

proper wear pad break-in and will normally not require further lubrication. However, after replacing any wear pad(s), or after prolonged periods of inoperation, light lubrication of the boom wear surfaces with a rust inhibitor/lubricant is recommended to keep the boom wear surfaces lubricated properly. Light lubrication of the boom wear surfaces is also recommended in salt air climates, and when the vehicle is stored, to help prevent rusting.

One such rust inhibitor that is specifically formulated for this purpose is LPS 3. It is marketed by:

LPS Laboratories, Inc.

4647 Hugh Howell Rd. Tucker GA 30085-5052 USA Phone: 1-800-241-8334 Fax: (770) 493-9206

2.60

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.13.20 Boom Chain Inspection

250

MS21702

MM2130

WARNING: Worn pins, stretched or

cracked links or corrosive environments can cause chain failure. A chain failure could result in uncontrolled boom movement, loss of load or vehicle instability and could cause death or serious injury and/or property damage.

Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation. Environmental conditions and dynamic impulse/shock loads can drastically affect normal operating conditions.

Environments in which material handling vehicles operate can vary widely from outdoor moisture to mildly corrosive or highly corrosive industrial atmospheres, in addition to abrasive exposures such as sand and grit.

• Moisture - Corrosive rusting reduces chain strength by pitting and cracking.

• Temperature - Low temperature reduces chain strength by making the metal brittle. Going in and out of cold storage results in moisture from condensation.

• Chemical Solutions or Vapors - Corrosive attack on the chain components and/or the mechanical connections between the chain components. Cracking can be (and often is) microscopic. Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time.

• Abrasives - Accelerated wearing and scoring of the articulating members of the chain (pins and plates), with a corresponding reduction in chain strength. Due to the inaccessibility of the bearing surfaces (pin surfaces and plate apertures), wear and scoring are not readily noticeable to the naked eye.

Dynamic shock loading can impose abnormal loads above the endurance limit of a leaf chain.

• High velocity movement of load, followed by sudden, abrupt stops.

• Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes, and rough terrain.

• Attempting to “inch” loads which are beyond the rated capacity of the vehicle.

Environmental conditions and load cycles make it impossible to predict chain life. Each specific application should be evaluated, based on the degree of exposure, the areas of possible operation and the types of load cycles.

A chain replacement schedule should be established to prevent chain failure. This schedule can be established by frequent inspection. Based on the observations, the frequency of inspection can be changed.

This inspection procedure development should go on until a projected time of replacement can be predicted. A chain by its very nature and exposure should be considered an expendable item and a safe chain replacement schedule established.

The boom chain’s normal life expectancy can be expressed as a maximum percent of elongation. This is generally 3% of pitch. As the chain flexes back and forth over the sheave, the bearing joints (pins and inside link plates) gradually incur wear due to articulation.

Inspection Guidelines

1. Park the vehicle on level ground. Place the travel select lever in [N] NEUTRAL, place the neutral lock lever in the [N] NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal (level) position.

2. Fully extend the boom until the extend chain is taut. Shut the engine off.

The extend chains will be visible for inspection with the vehicle in this state. The retract chain can be visually inspected, at the rear of the boom, as the boom is slowly retracted.

While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.

3. Inspect the chains for the following conditions:

Model MMV Rev. 12/04

2.61

General Information, Specifications and Maintenance

Elongation

When the original length (1) of 12.00" (305 mm) per foot of new chain has elongated from wear to a length (2) of 12.36" (313 mm), the chain should be discarded and replaced. (Refer to

Chain Replacement

Section 4.3.6, c.

It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation. Measuring the chain near its clevis terminals could give an inaccurate reading. The ends of the chains, near the clevis terminal, will not have flexed as frequently, if at all, as nearer the middle of the chains.

Measure across a span of 17 pins (16 links) at the center of the extend chain. Measure from pin center to pin center. Because the retract chain is inside the boom you will not be able to measure the chain.

The maximum measurement allowed is12.36" (313 mm). If the measurement is more than 12.36" (313 mm), the chain should be replaced. (Refer to

Section 4.3.6, c. Chain Replacement

Edge Wear

Check the chain for wear on the link plate edges caused by running back and forth over the sheave. The maximum reduction of material should not exceed 5%. This can be compared to a normal link plate height by measuring a portion of chain that does not run over the sheave.

The new chain link measures .713" (18 mm) (3). If the measurement of the worn chain is less than .677" (17 mm) (4), the chain should be replaced. (Refer to

Section 4.3.6, c. Chain Replacement

MM2050

2.62

MM2120

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

Turning or Protruding Pins

Highly loaded chain, operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates. When chain is allowed to operate in this condition, a pin or series of pins, can begin to twist out of a chain, resulting in failure.

Examine the pin head rivets to determine if the “VEE” flats are still in correct alignment (5). Chain with rotated/displaced heads (6) or abnormal pin protrusion (7) should be replaced immediately. (Refer to

Section 4.3.6, c. Chain Replacement

DO NOT attempt to repair the chain by welding or driving the pin(s) back into the chain. Once the press fit integrity between outside plates and pins has been altered, it cannot be restored.

Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system. This condition damages the chain as well as increases frictional loading and should be corrected.

Cracked Plates

Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain should be replaced in its entirety. (Refer to

4.3.6, c. Chain Replacement

It is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself.

MM2060

Section

• Fatigue Cracking - Fatigue cracks (8) are a result of repeated cyclic loading beyond the chain’s endurance limit. The size of the load and the frequency of its occurrence are factors which determine when fatigue failure will occur. The loading can be continuous or intermittent (impulse load).

• Stress Corrosion Cracking - The outside link plates are particularly susceptible to stress corrosion cracking (9). Like fatigue cracks, these initiate at the point of highest stress but tend to extend in an arc-like path between holes in the pin plate. More than one crack can often appear on a link plate. In addition to rusting, this condition can be caused by exposure to an acidic or caustic medium or atmosphere.

Stress corrosion is an environmentally assisted failure. Two conditions must be present: corrosive agent and static stress. In the chain, static stress is present at the aperture due to the press fit pin. No cyclic motion is required, and the plates can crack during idle periods.

• Corrosion Fatigue Cracking - Corrosion fatigue cracks are very similar to fatigue cracks (8) in appearance. They generally begin at the aperture and grow perpendicular to the chain pitch line. Corrosion fatigue is not the same as stress corrosion. Corrosion fatigue is the combined action of an aggressive environment and cyclic stress not a static stress alone, as in stress corrosion).

MM2070

Model MMV Rev. 12/04

MM2080

2.63

General Information, Specifications and Maintenance

Other Modes of Failure

• Ultimate Strength Failure - These types of failures are caused by overloads far in excess of the design load. Either fractured plates (1) or enlarged holes (2) can occur. If either of these failures occurs, chain should be replaced immediately. (Refer to

Replacement

Section 4.3.6, c. Chain

• Tight Joints - All joints in the chain should flex freely. Tight joints (3) resist flexing and increase internal friction, thus increasing chain tension required to lift a given load. Increased tension accelerates wear and fatigue problems.

If the problem is caused by dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re-installing the chain.

If the problem is caused by corrosion and rust or bent pins, replace the chain. (Refer to

4.3.6, c. Chain Replacement

Section

MM2090

2.13.21 Boom Chain Tension & Adjustment

a. Boom Chain Tension Check

0001

MS21902 MT1750

2. Fully extend the boom, then retract it 2" (51 mm) (one inch per section). Shut the engine off.

3. Measure the sag (4) in the top extend chains between the bottom of the chains and the top of the intermediate boom (5) at their closest point. Acceptable boom chain sag is between 1.5-2.5" (38-64 mm). If the measurement is less than 1.5" (38 mm), the boom chains may need to be adjusted. Before making any adjustment to the extend chains, check the following measurement at the rear of the boom, as described in Steps 4-9.

MM2100

MM2110

2.64

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

OA0491

4. Start the engine, retract the boom completely and turn the engine OFF.

5. Open the door at the rear of the vehicle.

6. Check the measurement (6) from the rear of the intermediate boom to the rear of the inner boom. This measurement should be in the range of 8.5-9.0" (216-229 mm).

If the intermediate boom to the inner boom measurement is less than 8.5" (216 mm), the boom may require extensive adjustment and/or repair. Contact the JLG Service Department or the nearest JLG Authorized Service Center (ASC).

If the intermediate boom to the inner boom measurement is greater than 9.0" (229 mm), tighten the retract chain locknut (7) located on the bottom front of the outer boom (8).

OT07602

OT04902

7. Start the vehicle and cycle the boom in and out several times. Then with the boom horizontal, retract the boom completely. Turn the engine OFF.

8. Recheck the measurement (6) at the rear of the boom between the intermediate and inner boom. If the measurement is still more than 9.0" (229 mm), repeat Steps 2-6.

Note: If by adjusting the retract chain locknut (7) you cannot obtain the measurement within the range of

8.5-9.0" (216-229 mm), the boom (8) may require extensive adjustment and/or repair. Contact the JLG Service Department or the nearest JLG Authorized Service Center (ASC).

Model MMV Rev. 12/04

If the measurement is within the range of 8.5-9.0" (216229 mm), measure the top boom extend chain sag again.

2.65

General Information, Specifications and Maintenance

9. Start the vehicle, cycle the boom in and out several times. With the boom horizontal, fully extend the boom and then retract it 2" (51 mm) (one inch per section). Turn the engine OFF.

OA0491

10. Measure the sag (1) in the top extend chains between the bottom of the chains and the top of the intermediate boom (2) at their closest point. Acceptable boom chain sag is between 1.5-2.5" (38-64 mm). If the measurement is less than 1.5" (38 mm), the top boom extend chains may need to be adjusted. (Refer to

Chain Adjustment

Section 2.13.21, b. Extend

2. Adjust the top extend boom chains by tightening the locknuts (3), located at the rear of the boom (4). Be sure each locknut is tightened equally, so that each chain maintains the same tension.

OT05002

3. Equal boom extend chain (5) tension can be checked by the position of the yoke (6) on the outer boom. The front of the yoke should be parallel with the front of the front edge of the outer boom.

b. Extend Chain Adjustment

Note: Always perform the “Boom Chain Tension Check”

Refer to Section 2.13.21, a. Boom Chain Tension Check, before adjusting the boom chain tension.

1. Park the vehicle on level ground. Place the travel select lever in the [N] NEUTRAL position, place the neutral lock lever in the [N] NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal boom. Retract the boom completely and turn the engine OFF.

2.66

OT07702

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

4. Start the engine and cycle the boom in and out several times. With the boom horizontal, fully extend the boom and then retract it 2" (51 mm) (one inch per section). Turn the engine OFF.

5. Measure the chain sag. Acceptable boom chain sag is between 1.5-2.5" (38-64 mm). If the measurement is less than 1.5" (38 mm), repeat Steps 2-5 until the sag is within acceptable range.

Note: If the top boom extend chain sag cannot be adjusted within the acceptable range of 1.5-2.5" (38-64 mm), the boom may require extensive adjustment and/or repair. Contact the JLG Service Department or the nearest JLG Authorized Service Center (ASC).

IMPORTANT: With the boom extended fully, apply “LUBRIPLATE” Chain & Cable Fluid, “LPS3” or equivalent or equivalent to the two extend chains.

6. Close the rear door.

2.13.22 Chain Lubrication

0001

MS21902 OM1480

After inspection and before being returned to service, chains must be lubricated with a quality chain lubricant (“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or equivalent).

The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to the external surfaces will prevent rust, but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links.

To prepare the chain for lubrication, the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that lubricant can penetrate to the working surfaces.

Lubricant may be applied with a narrow paint brush or directly poured on, but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces. All surplus lubricant should be wiped away from the external surfaces. DO NOT use a solvent for this wiping operation.

Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated. In extremely dusty conditions, it may be necessary to lubricate the chains more often.

Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration. It is important that a reputable lubrication specialist, an authorized JLG Authorized Service Center (ASC) or the vehicle distributor be consulted for guidance.

Model MMV Rev. 12/04

2.67

General Information, Specifications and Maintenance

2.13.23 Short Term Storage

Less Than Two Months Duration

a. Before Storing

Perform the following steps prior to placing the vehicle in storage:

1. Clean the entire vehicle. DO NOT remove the grease coating from the boom chains.

2. Lubricate all grease fittings as described in

2.13.1, c. 250 Hour Intervals

3. Prepare the engine for storage (refer to the engine manual).

4. Apply multi-purpose grease to all exposed hydraulic cylinder rods.

5. Apply Teflon based lubricant to the fork shafts and the fork slide plates.

6. If the ambient temperature, anytime during the storage period is expected to drop to a point that the batteries could freeze, remove the batteries from the vehicle. Store the batteries in a dry place where they are not subject to temperatures near or below freezing.

7. If the ambient temperature is expected to remain above freezing and the vehicle is to be stored less than one month, the batteries can remain connected and no further disconnection of the equalizer is required.

8. If the ambient temperature is expected to remain above freezing and the vehicle is to be stored more than one month, but less than two months, the batteries can remain connected. However, the NEGATIVE (-) lead to the bottom of the equalizer must be disconnected to prevent electrical draw on the batteries. Save the capscrew, lockwasher and hex nut for reassembly. Isolate the cable away from the equalizer.

9. If the ambient temperature is expected to drop below freezing at anytime during the storage period, make sure the engine coolant is either completely drained from the radiator and engine block or that the amount of anti-freeze in the system is adequate to keep the coolant from freezing.

10. Preferably, store the vehicle inside where it will remain dry. If it must be stored outside, park it on lumber laid on flat level ground or on a concrete slab and cover with a tarp.

Section

b. B. Removing From Storage

After removing the vehicle from storage and before operating it, perform the following steps:

1. Reinstall a properly charged batteries (if removed). Secure the hold-down brackets and attach battery cables.

2. If the NEGATIVE (-) lead to the equalizer was disconnected, reconnect the lead to the NEGATIVE (-) terminal and secure with the capscrew, lockwasher and hex nut saved from putting the vehicle into storage. Torque the hex nut to 100 lb/in (11 Nm).

3. Change the engine oil and filter to remove condensation or other residuals.

4. If the vehicle has been stored for two years or more, drain the coolant from the engine block and radiator and refill with a 50/50 mixture of fresh anti-freeze and water. For detailed information, see

2.13.4, b. Drain and Flush the Radiator

5. Wipe off any multi-purpose grease that was applied to vehicles hydraulic cylinder rods prior to storing.

6. Refer to perform all the maintenance checks listed under the 10 Hour Intervals.

7. Review and familiarize yourself and any other operator with all the safe and proper operating procedures contained in the Sky Trak MMV Telescopic Material Handler Owners/Operators Manual.

Section 2.13.1, a. 10 Hour Intervals

Section

and

2.13.24 Long Term Storage

Two Months Duration or More

a. Before Storing a Vehicle

Perform the following steps prior to placing the vehicle in storage:

1. Clean the entire vehicle. Clean and dry all surfaces to be sprayed with transit coat, but DO NOT remove the grease coating from the boom chains.

2. Lubricate all grease fittings as described in

2.13.1, c. 250 Hour Intervals

3. Thoroughly clean all four tires (side walls and tread area) removing all dirt and debris. Be sure the tires are free of grease and oil residue.

Section

2.68

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

4. Coat the tires with a anti-ozone protectant coating. One of the recommended coatings is #G9588 “Black Rubber Preservative” from the Akron Paint and Varnish Company. Apply the protectant coating per the application instructions on the container.

Akron Paint and Varnish Company

1390 Firestone Parkway Akron, OH 44301 Phone: (216) 773-8911

5. Allow the coating to dry per instructions on the container, rotate the tires by moving the vehicle forward or backward. Coat the area of each tire that was in contact with the ground.

6. Prepare the engine for storage (refer to the engine manual).

7. Apply multi-purpose grease to all exposed hydraulic cylinder rods.

8. Seal all other exposed unpainted and plated metal with transit coat including surfaces that are accessible with boom, hydraulic tank, engine and transmission covers open or battery covers removed. Unpainted surfaces include boom chains and chain clevis’. Plated surfaces including pin ends, fastener hardware, hydraulic tubes, fittings and hose ends should also be coated.

9. Apply a coating thickness of .003" to .005" (0,08 to 0,1 mm). Allow one to fifteen minutes to dry, depending on temperature, humidity and coating thickness.

Note: Overspray will not harm paint, rubber and glass and will be easily removed.

10. Apply Teflon based lubricant to the fork shafts and the fork slide plates.

11. Disconnect the battery cables. Remove the batteries from the vehicle and store in a dry place where they are not subject to temperatures near or below freezing.

12. If the ambient temperature is expected to drop below freezing at anytime during the storage period, make sure the engine coolant is either completely drained from the radiator and engine block or that the amount of anti-freeze in the system is adequate to keep the coolant from freezing.

13. Preferably, store the vehicle inside where it will remain dry. If it must be stored outside, park it on lumber laid on flat level ground or on a concrete slab and cover with a tarp.

b. Removing Vehicle from Storage

After removing the vehicle from storage and before operating it, perform the following steps:

Parts of this vehicle have been sprayed with a clear protective “transit” coating prior to being stored. Removing the transit coating will prevent discoloration. If you do not remove the transit coating it will not harm the vehicle.

The transit coating has been sprayed primarily onto plated metal parts such as brackets, pulleys, hose connections, pipe fittings and hardware. Some overspray will have settled on the surrounding areas. Before removing the transit coating, read all removal information and material data safety sheets supplied with the transit coating decoater gun.

1. To remove the transit coating, refer to the following steps.

a. Wear the recommended

safety equipment, rubber gloves and eye protection.

OM1410

b. Assemble the transit coating

decoater gun.

OM1420

c. Dilute the transit coating

remover with water 1:6. Position the vehicle in a shaded area. DO NOT pre-rinse with water. Spray the coated areas thoroughly.

OM1430

d. Wait two - three minutes,

keeping the coated areas wet the full two - three minutes.

2-3

MINUTES

OM1440

e. Remove the transit coating

remover bottle and rinse the

H O

vehicle thoroughly with water.

OM1450

Model MMV Rev. 12/04

2.69

General Information, Specifications and Maintenance

2. Reinstall the properly charged batteries. Secure the hold-down brackets and attach battery cables.

3. Change the engine oil and filter to remove condensation or other residuals.

2.13.4, b. Drain and Flush the Radiator

5. Wipe off any multi-purpose grease that was applied to the vehicles hydraulic cylinder rods prior to storing.

6. Refer to perform all the maintenance checks listed under the 10 Hour Intervals.

7. Review and familiarize yourself and any other operator with all the safe and proper operating procedures contained in the Sky Trak MMV Telescopic Material Handler Owners/Operators Manual.

Section 2.13.1, a. 10 Hour Intervals

Section

and

OM1160

Note: Record the number of flat washers on each capscrew as they are removed. The correct number of flat washers must be reassembled in the same locations to ensure proper capscrew protrusion during reassembly of the counterweight.

2.13.25 Counterweight Removal and Reassembly

a. Removal

Certain transport applications will require counterweight removal. When removing the counterweight, another piece of equipment (such as another MMV) capable of lifting 5,000 lbs (2268 kg) will be required.

1. Park the vehicle on level ground, frame sway the vehicle to 0° and ground the carriage.

2. Place the travel select lever in [N] NEUTRAL, place the neutral lock lever in the [N] NEUTRAL LOCK position, engage the parking brake switch and turn the engine OFF.

3. Using another piece of equipment, lift a pallet (1) up underneath the counterweight. Lift the pallet up to the counterweight, but DO NOT put pressure on the counterweight.

4. Remove the four capscrews (2) and flat washers (3) securing the counterweight (4) to the vehicle frame. Remove and clean any Loctite® threadlocker residue from the threads of each capscrew and bushing.

5. The four threaded bushings (5) will remain in place in the frame until the counterweight has been removed.

6. Lower the counterweight down with the pallet.

7. Remove the four threaded bushings (5) from the frame.

Note: When securing the counterweight to the pallet, be sure to secure the counterweight insert (6). The counterweight insert is located in a “pocket” inside the counterweight. The insert weighs 500 lbs (227 kg).

Note: If a white, powdery residue is present on the threads, it can be removed. Use “Methylene Chloride” to soften the residue and clean the residue from the threads with a soft brass wire brush.

2.70

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

b. Assembly

IMPORTANT: When applying the Loctite® threadlocker

to the threads of the bushing and the capscrews you have a maximum of ten minutes to line the counterweight up and insert all four capscrews. The threadlocker will start to set-up after ten minutes.

1. Insert the four threaded bushings (5) into the square holes in the vehicle frame. Apply a few drops of Loctite® threadlocker #277 to the threads of each bushing.

2. Be sure the counterweight insert (6) is in place in the “pocket” inside the counterweight.

3. With the counterweight on the transport pallet (1), use another piece of equipment to lift the pallet up. Line up the holes in the counterweight (4) with the threaded bushings.

4. Apply Loctite® threadlocker #277 to 1-1/2" of the engaging threads of each capscrew (2).

5. Assemble the flat washers (3) onto the capscrews (2) and insert the capscrews with flat washers into the mounting holes in each side of the counterweight. Thread the capscrews into the threaded bushings (5) in the frame. Torque all capscrews to 680 lb/ft (922 Nm).

Model MMV Rev. 12/04

2.71

General Information, Specifications and Maintenance

2.13.26 Transport

When transporting the vehicle, make use of all tiedown/ lift point locations on the vehicles frame.

Note: The user assumes all responsibility for choosing the proper method of transportation, and the proper selection and use of transportation and tiedown devices, making sure the equipment used is capable of support-

MIRROR TO BE ROTATED INWARD

27.0" (686 mm) (B)

28.6" (726 mm) (A)

FRONT VIEW SHOWN WITHOUT

TIEDOWN / SLING B

13.5" (343 mm) (B)

14.3" (363 mm) (A)

BOOM FOR CLARITY

15.5"

(394 mm)

ing the weight of the vehicle being transported and that all manufacturer’s instructions and warnings, regulations and safety rules of their employer, the Department of Transportation and/or any other state or federal laws are followed.

MIRROR TO BE ROTATED INWARD

93.6" (2377 mm) MAX HEIGHT

12.0" (305 mm) (D)

28.6" (726 mm) (C)

SLING D

TIEDOWN C

100.2"

(2545 mm)

MAX WIDTH

24.0" (610 mm) (D)

14.3" (363 mm) (C)

74.8"

(1900 mm)

54" (1372 mm)

REF

47.3" (1201 mm)

41.0" (1041 mm)

33.0" (838 mm)

55.3" (1405 mm)

OM1151

TIEDOWN A

14.4"

(366 mm)

STANDARD 96" COMMERCIAL

TRAILER SHOWN

DISTANCE

131.0"

(3327 mm)

30.5"

(775 mm)

41.5"

(1054 mm)

For the different modes of transportation, refer to the proper section required. The different modes are.

• Truck Transportabilty. Refer to “Truck Transportability” on page 2.73.

• Rail Transportability and GIC Clearance. Refer to “Rail Transportability and GIC Clearance” on page 2.73.

• Air Transport, C-17, C141 or C-5 Tiedowns. Refer to

• Air Transport, C-130 Configuration. Refer to “Air

Transport, C-130 Configuration” on page 2.75.

• Marine Transportability. Refer to “Marine Transportability” on page 2.76.

• External Transport/Slinging. Refer to “External Transport/Slinging” on page 2.76.

“Air Transport, C-17, C141 or C-5 Tiedowns” on page 2.74.

2.72

Model MMV Rev. 12/04

a. Truck Transportability

MIRROR TO BE ROTATED INWARD

General Information, Specifications and Maintenance

MIRROR TO BE ROTATED INWARD

93.6" (2377 mm) MAX HEIGHT

100.2"

(2545 mm)

MAX WIDTH

b. Rail Transportability and GIC Clearance

NORTH AMERICAN RAIL TRANSPORT GAUGE

APPROX. 45°

STANDARD 96" COMMERCIAL

TRAILER SHOWN

MIRROR TO BE ROTATED INWARD

TIRE PROTECTIVE MATERIAL

54" (1372 mm)

REF

NATO GIC EQUIPMENT GAUGE

OM1251

Model MMV Rev. 12/04

50" (1270 mm)

OM1261

2.73

General Information, Specifications and Maintenance

c. Air Transport, C-17, C141 or C-5 Tiedowns

111"

(2819 mm)

103"

(2616 mm)

103"

(2616 mm)

AFT OPENING

DESIGN LIMITS

FS 734, 958, 998 & 1058

111.25" (2826 mm) MAXIMUM

TYPICAL SECTION

103"

(2616 mm)

OM1280

2.74

212019 22 282524 2726 3029 31 32 3533 34 3736 3938

L12

L10

L13

L14

FS 678 434

292

322 CD

FUS. STA.

L11

L15

398E458 578518

L16

1058

678I735

818K898

958

998

LMN

1178P1258 1412RQ1338 1543S1478

L32

L30

L24

L20

L17

L31

L28

L29

L27

L26

L25

L22

L23

L19

L21

L18

Axle Load

Load/Tire

Footprint Area

@ 87 psi

Axle and Tire Data

Axle Rear Front

15,700 lbs (7.121 Kg)

7,850 lbs

(3.561 Kg)

123 sq in

(793 cm

)

14,800 lbs (6.713 Kg)

7,400 lbs

(3.357 Kg)

119 sq in

(768 cm2)

OM1271

Model MMV Rev. 12/04

d. Air Transport, C-130 Configuration

CLEARANCE ENVELOPE

BOTH MIRRORS TO

BE ROTATED IN

General Information, Specifications and Maintenance

SAFETY AISLE

2345678910

FS245 281

CARGO ENVELOPE

337

105" (2667 mm)

MAXIMUM

VIEW LOOKING REARWARD

THROUGH AIRCRAFT

LASH COUNTERWEIGHT, COUNTERWEIGHT INSERT AND CARRIAGE SECURELY.

11 12 13 1614 15 17 18 19 2120 22

L11

L16

457

HEIGHT ENVELOPE

L12

517

L10

L13

L14 L15

401

597 68 2

(2591 mm)

627

102"

For axle and pallet weights refer to the following tables.

Axle and Tire Data

Axle Rear Front

Axle Load

Load/Tire

Footprint Area

@ 87 PSI

23 24 25

L32

L31

L29

L28

L30

L27

L26

L25

L24

L22

L23

L20

L19

L21

L17

L18

737

463L Pallet Weight

7,000 lb Fork

Carriage Weight

Counterweight

Assembly Weight

Counterweight

Insert Weight

11,100 lbs (5.035 Kg)

5,550 lbs

(2.517 Kg)

101 sq in

(652 cm

463L Pallet Data

To t a l We ig ht

12,200 lbs (5.534 Kg)

(2.767 Kg)

)

(677 cm2)

290 lbs

(131 Kg) 2,500 lbs

(1134 Kg)

4,200 lbs

(1905 Kg)

500 lbs

(227 Kg) 7,490 lbs

(3397 Kg)

6,100 lbs

105 sq in

Model MMV Rev. 12/04

OM1291

2.75

General Information, Specifications and Maintenance

e. Marine Transportability

APPROX. 45°

f. External Transport/Slinging

OM1331

15.5"

(394 mm)

47.3"

(1201 mm)

DISTANCE

131.0"

(3327 mm)

TILT ANGLE

Carriages

Both Carriages

(7 K) 48" Load

Center Carriage

(11 K) 24" Load

Center Carriage

(1900 mm)

41.0"

(1041 mm)

41.5"

(1054 mm)

74.8"

Distance

67.25"

(1708 mm)

73.25"

(1860 mm)

78.75"

(2000 mm)

Tilt

Angle

2.0°

5.0°

7.0°

Weight

30,500 lbs

(13.835 Kg)

29,300 lbs

(13.290 Kg)

28,100 lbs

(12.746 Kg)

CH-53

Not Allowed

CH-53

Not Allowed

CH-53

Approved

OM1341

2.76

Model MMV Rev. 12/04

2.14 EMERGENCY OPERATIONS

General Information, Specifications and Maintenance

2.14.1 Towing a Disabled Vehicle Short Distances

Towing a disabled vehicle should only be attempted as a last resort, after exhausting all other options. Every effort should be made to repair the vehicle and move it under its own power. Towing the vehicle improperly can result in damage to the vehicle drivetrain.

IMPORTANT! In the event the vehicle is disabled and cannot be moved under engine power, the situation must be properly evaluated and dealt with on an individual basis. Contact your local (ASC) or the for specific instructions for your particular situation.

If it is necessary to tow the vehicle a short distance to avoid a potentially hazardous situation such as being in an unsafe area on the worksite or on a roadway, prepare the vehicle for towing as follows;

1. Remove the load from the vehicle.

2. Fully retract the boom. Position forks approximately 24" above ground. (Refer to

Emergency Boom Lowering and Retracting

proper procedure if required.)

3. Open the engine compartment cover. Allow the hydraulic oil to cool.

JLG

Service Department at (877) 554-5438

JLG

Authorized Service Center

Section 4.3.10,

for

CAUTION: DO NOT exceed 650 psi

(45 bar) when pressurizing the park brake. Applying too much pressure may damage the brake seals.

8. Turn the steering wheel until the front tires are pointed in a straight ahead position.

WARNING: DO NOT open the rear

door with the air conditioner rocker switch in the ON position and the fan switch turned to the ON position. Contact with moving parts can cause death or serious personal injury.

OM1051

WARNING: BLOCK ALL FOUR

WHEELS. Failure to do so could result in death or serious injury from vehicle roll-away.

4. Block all four wheels to help prevent the vehicle from moving after the parking brake is disabled.

5. Locate the emergency towing pressurizing valve (1) located under the radiator on the mounting bracket.

6. Turn the ignition switch to the ON position (with the engine not running), release the parking brake switch.

Note: With the ignition switch in the ON position, the low brake pressure buzzer will sound continuously until the towing operation is complete and ignition switch turned to the OFF position.

7. Use the handle (2) on the emergency towing valve to pump pressure into the system. Watch the pressure gauge (3) while pumping pressure into the park brake system. DO NOT exceed 650 psi (45 bar).

9. Open the rear door. Connect the steer cylinder crossover tow hoses (4) together. The two hoses are located inside the rear of the frame.

OM1080

Model MMV Rev. 12/04

2.77

General Information, Specifications and Maintenance

10. Remove the dust cap (1) from the “male” nipple on one crossover hose. Remove the dust cap (2) from the “female” quick disconnect on the other crossover hose. Couple the quick disconnects together. Close the rear door.

11. With the crossover hoses (3) coupled together, the rear wheels will be free to steer, thus “tracking” as the vehicle is being towed.

WARNING: DO NOT tow at speeds

over 20 mph. Carefully move the towing vehicle into position. Always use a ground guide and any device necessary to lift the tow bar into position without standing directly between vehicles. Failure to comply could result in vehicle damage, or injury or death to personnel.

12. Clear the area of any unnecessary personnel.

13. Carefully remove the wheel blocks from each of the four tires. Tow the vehicle to a secure location.

14. Have an operator seated in the seat.

15. The vehicle can now be towed out of the way using the pintle hook provided on the rear of the vehicle.

Tow or push the vehicle at a very slow speed!

WARNING: Always disconnect the

steer cylinder crossover hoses before resuming normal operation. Failure to disconnect the crossover hoses will result in the inability to steer the rear wheels. If the vehicle is driven in this condition, control of the rear wheels will be unpredictable.

WARNING: DO NOT open the rear

door with the air conditioner rocker switch in the ON position and the fan switch turned to the ON position. Contact with moving parts can cause death or serious personal injury.

OM1080

2.14.2 Towing a Disabled Vehicle Long Distances

IMPORTANT! In the event the vehicle is disabled and cannot be moved under engine power, the situation must be properly evaluated and dealt with on an individual basis. Contact your local

JLG

(ASC) or the for specific instructions for your particular situation.

If it is necessary to tow the vehicle a long distance to a repair facility, prepare the vehicle for towing as follows;

1. Remove the load from the vehicle.

2. Fully retract the boom. Position forks approximately 24" above ground. (Refer to

Emergency Boom Lowering and Retracting

proper procedure if required.)

Service Department at (877) 554-5438

JLG

Authorized Service Center

Section 4.3.10,

for

16. Before placing the vehicle back into service, disconnect the steer cylinder crossover hoses (3) by removing the “male” nipple from the “female” coupler. Re-install both dust caps (1 and 2). Perform the steer indexing procedures. (Refer to

Steer Indexing Procedures

2.78

Section 9.9,

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

WARNING: BLOCK ALL FOUR

WHEELS. Failure to do so could result in death or serious injury from vehicle roll-away.

3. Block all four wheels to help prevent the vehicle from moving after the parking brake is disabled.

4. Remove the four bolts (4) and two straps (5) securing the bearing crosses to the front and rear axle input yokes (6).

5. Secure the unattached end of the drive shaft (7) in hanger hook (8) provided underneath the frame of the vehicle. Rotate the hanger hooks into position to hold the driveshaft. The hanger hooks have spring tension applied to hold them in position

9. Use the handle (10) on the emergency towing valve to pump pressure into the system. Watch the pressure gauge (11) while pumping pressure into the park brake system. DO NOT exceed 650 psi (45 bar).

CAUTION: DO NOT exceed 650 psi

(45 bar) when pressurizing the park brake. Applying too much pressure may damage the brake seals.

6. Turn the ignition switch to the ON position (with the engine not running), release the parking brake switch.

Note: With the ignition switch in the ON position, the low brake pressure buzzer will sound continuously until the towing operation is complete and ignition switch turned to the OFF position.

7. Open the engine compartment cover. Allow the hydraulic oil to cool.

8. Locate the emergency towing pressurizing valve (9) located under the radiator on the mounting bracket.

MM2220

OM1051

10. Turn the steering wheel until the front tires are pointed in a straight ahead position.

WARNING: DO NOT open the rear

door with the air conditioner rocker switch in the ON position and the fan switch turned to the ON position. Contact with moving parts can cause death or serious personal injury.

11. Open the rear door. Remove the dust cap (1) from the “male” nipple on one crossover hose. Remove the dust cap (2) from the “female” quick disconnect on the other crossover hose. Couple the quick disconnects together.

12. With the crossover hoses (3) coupled together, the rear wheels will be free to steer, thus “tracking” as the vehicle is being towed.

Model MMV Rev. 12/04

2.79

General Information, Specifications and Maintenance

13. Close the rear door.

WARNING: DO NOT tow at speeds

14. Position the towing vehicle in place. Using the tow lugs, located at the rear of the vehicle, connect the tow bar to the disabled vehicle.

15. Clear the area of any unnecessary personnel.

16. Carefully remove the wheel blocks from each of the four tires. Tow the vehicle to a secure location.

17. Have an operator seated in the seat.

IMPORTANT! Tow or push the vehicle at a very slow speed!

WARNING: DO NOT open the rear

door with the air conditioner rocker switch in the ON position and the fan switch turned to the ON position. Contact with moving parts can cause death or serious personal injury.

18. Before placing the vehicle back into service, disconnect the steer cylinder crossover hoses (1) by removing he “male” nipple from the “female” coupler. Re-install both dust caps (2 and 3).

19. Re-install the ends of the drive shafts (4) to the front and rear axle input yokes (5) using the straps (6) and bolts (7) removed in step 4. Torque the M12 bolts to 156 lb/ft (212 Nm). Rotate the driveshaft hanger hooks out of the way and install the driveshafts to the front and rear axles.

20. Perform the steer indexing procedures. (Refer to

Section 9.9, Steer Indexing Procedures

MM2220

2.14.3 Boom Lowering and Retracting

In the event of total loss of engine power or hydraulic pump failure, emergency boom lowering procedures are listed in

Section 4.3, Boom Assembly Maintenance

conditions requiring emergency boom lowering are addressed; Engine or Hydraulic Pump Failure (refer to

Section 4.3.10, a. Engine or Hydraulic Pump Failure

Hydraulic Line Failure (refer to

Hydraulic Line Failure

Section 4.3.10, b.

IMPORTANT: In the event of total loss of engine power or hydraulic pump failure with an elevated load, properly evaluate and deal with each situation on an individual basis. Contact the nearest JLG Authorized Service Center (ASC) or the JLG Service Department for specific instructions.

. Two types of

) or

2.80

OM1080

Model MMV Rev. 12/04

General Information, Specifications and Maintenance

2.15 PARKING BRAKE/TRANSMISSION DE-CLUTCH TEST PROCEDURES

To check that the parking brake/transmission de-clutch system is functioning properly, perform the following tests.

IMPORTANT: These tests should be performed in [1] FIRST gear only.

WARNING: DO NOT operate this

vehicle unless you are in the seat with the seat belt fastened around you. Death or serious personal injury could result if the belt is not securely fastened.

Test 1 - Transmission De-Clutch

Step 1

a. Place the vehicle on a level surface.

b. Clear the area in front and behind the vehicle of

any obstacles.

c. Fasten your seat belt.

d. Push and turn the ignition switch 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.

Step 2

a. Remove your foot from the throttle pedal.

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.

Test 2 - Transmission De-Clutch/Parking

Brake Activation

a. With the vehicle unloaded, disengage the park-

ing brake.

b. Move the travel select lever to [F] FORWARD.

c. Move the unit slowly

(approximately 1 mph [1,6 kmh]).

d. Engage the parking brake. The unit should stop

abruptly.

Test 3 - Park Brake Hold Performance

a. With the rated load of 11,000 lbs (4.989 Kg) on

the forks, drive the vehicle forward up a 15% grade (15 ft. rise over 100 ft. run).

in a forward direction

b. Stop the vehicle using the service brakes, apply

the park brake, shift the transmission into NEUTRAL (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 to the OFF position and back down off the grade.

e. Repeat “Test 3” by backing up the grade and

checking the park brake holding performance.

If the parking brake or transmission de-clutch does not pass these tests, do the following.

1. Immediately

remove the vehicle from service.

WARNING: BLOCK ALL FOUR

WHEELS. Failure to do so could result in death or serious personal injury from vehicle roll away.

2. Block all four wheels to prevent the vehicle from moving.

3. Place the accident prevention tags (8) on the ignition switch and the steering wheel.

4. Service the parking brake immediately or contact your local JLG Authorized Service Center (ASC) to repair the system.

DANGER

OM1510

Model MMV Rev. 12/04

2.81

General Information, Specifications and Maintenance

This Page Intentionally Left Blank

2.82

Model MMV Rev. 12/04

Section 3

Cab, Covers and Mirrors

Contents

PARAGRAPH TITLE PAGE

3.1 Operator’s Cab and Covers Component Terminology. . . . . . . . . . . . . . . . . . . . . 3.2

3.2 Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.2.1 Operator’s Cab Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.2.2 Serial Number Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.2.3 Cab Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

3.3 Operator’s Seat and Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24

3.3.1 Seat Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24

3.3.2 Seat Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24

3.4 Cab Heater/Air Conditioning Blower Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

3.4.1 Blower Box Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

3.4.2 Blower Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28

3.5 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30

3.5.1 Steering Wheel, Column and Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30

3.5.2 Joystick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

3.5.3 Service Brake Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40

3.5.4 Throttle Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

3.6 Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43

3.6.1 Mirror Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43

3.6.2 Mirror Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43

3.7 Access Panels, Covers and Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

3.7.1 Cover and Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

3.7.2 Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

Model MMV Rev. 12/04

3.1

Cab, Covers and Mirrors

3.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the major assemblies of the vehicle cab and covers. The following illustration identifies the components that are referred to throughout this section.

Engine Hood

Rear Cover

Operator’s Protective Structure

Mirror

Accelerator Pedal

Service Brake

Steering Wheel

Seat

Multi-Function Joystick

MM1771

3.2

Model MMV Rev. 12/04

JLG sky trak mmv Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

EFFECTIVITY PAGE