JLG sky trak mmv Service Manual
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
Model MMV Rev. 12/17
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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
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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
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Section Subject Page
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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
1
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
1
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
2
DANGER
D
A
N
G
E
R
3
1
1
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.
O
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.
L
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.
C
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.
H
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.).
F
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.
C
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.
E
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.
V
ENTILATION: Avoid prolonged engine operation in en-
closed areas without adequate ventilation.
R
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.
S
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
F
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.
P
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.
L
EAVING VEHICLE: Lower the attachment to the ground
before leaving the vehicle.
T
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
.
2
.
3
.
4
1
0
9
7
9
1
1
3
2
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.
6
9
5
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 operators manual
before operating.
2. Fasten seat belt.
MAINTAIN
proper tire
pressure at
all times.
8
10
3. Allow no riders.
4. Use an approved work
platform to lift or lower
personnel.
7
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
or
International: 1-717-485-5161
MOVING PARTS can cut.
11
Keep clear of fan and belts
while engine is running.
MOVING PARTS can entangle.
14
2.
1.
12
15
3.
4109791
Allow no riders.
A
4
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
13
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)
B
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.
1
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)
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 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
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.
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
2
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)
2
) 0.09 Square meters (m2)
2
) 0.8 Square meters (m2)
2
) 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)
3
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
3
Cubic feet (ft
Cubic yards (yd
) 0.03 Cubic meters (m3)
3
) 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
2
) 0,4 Square inches (in2)
(cm
Square meters (m
2
) 1,1 Square yards (yd2)
Square kilometers
2
(km
) 0,6 Square miles (mi2)
2
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)
3
Milliliters (ml) 0,06 Cubic inches (in
)
Liters 2,1 Pints (pt)
Liters 1,06 Quarts (qt)
Liters 0,26 Gallons (gal)
3
Cubic meters (m
Cubic meters (m
) 35 Cubic feet (ft3)
3
) 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)
(C) Height (Boom Lowered) 93" (2.362 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
T
M
I
U
P
J
N
0.0
Q
V
R
F
K
W
D
A
C
S
O
L
Model MMV Rev. 12/04
EB
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
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