SkyTrak 10042 Operation Manual

OWNERS/OPERATORS

MANUAL

Model 10042 (S/N 19031 thru 19971 and S/N 0160002407 thru 0160029583)

OH1562

Keep this manual with the vehicle at all times.

8990501 C

Printed in U.S.A. 2/07

WARNING: Improper operation of this vehicle can cause injury or death. Only trained and authorized operators should operate this vehicle.

Before starting the engine, do the following:

1.Read this owner/operators manual.

2.Read all the safety decals on the vehicle.

3.Clear the area of other persons.

Learn and practice safe use of vehicle controls in a safe, clear area before you operate this vehicle on a worksite.

It is your responsibility to observe applicable laws and regulations and to follow manufacturer's instructions on vehicle operation and maintenance.

CALIFORNIA

Proposition 65 Warning

Diesel Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

CALIFORNIA

Proposition 65 Warning

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

Table of Contents

Introduction
The Manual....................................	2
Replacement Parts ........................	2
Reports ..........................................	2
Safety Practices
Disclaimer......................................	3
Hazard Classification System........	3
Accident Prevention Tags..............	5
New or Additional Operators .........	5
Instructional Symbols ....................	6
Hazard Symbols ............................	7
Avoidance Symbols .......................	8
Avoidance Symbols (cont’d) ..........	9
Personal Considerations .............	10
Operational Considerations .........	14
Equipment Considerations ..........	21
Operation
Operator Controls ........................	24
Instruments and Indicators ..........	37
Optional Controls.........................	47
Pre-Operation Inspection.............	57
Normal Starting............................	58
Cold Starting................................	59
Jump Starting ..............................	60
Refueling .....................................	61
Stabil-TRAK System....................	63
Operating.....................................	66
Using The Capacity Chart ...........	74
Fork Ratings ................................	87
How To Pick, Carry & Place A
Load..........................................	88
Elevating Personnel.....................	88
Using Other Attachments ............	93
Shut-Off .......................................	94
Emergency Operations
Towing A Disabled Vehicle..........	95
Emergency Boom Lowering ........	97
General Maintenance
General Maintenance ................	110
Maintenance Schedule And
Checklist .................................	111
1. Lubrication Points..............	116
2. Air Cleaner & Restriction
Indicator.............................	118
3. Engine Cooling System .....	122

4.	Engine Oil And Filter .........	125
5.	Engine Fuel System ..........	129
6.	Engine Fan Belt.................	134
7.	Hydraulic Oil and Filter......	135
8.	Transmission Oil and
	Filter ..................................	139
9.	Axle Oil..............................	142
10.	Brake Disk Inspection .......	144
11.	Wheel End Oil ...................	148
12.	Wheels and Tires ..............	150
13.	Batteries ............................	152
14.	Fuse and Relay
	Replacement .....................	154
15.	Boom Chains and Wear
	Pads ..................................	158
Storage and Transport ..............		173
Storage......................................		173
Transport ...................................		174
Test Procedures
Stabil-TRAK System Test..........		175
Parking Brake/Transmission
De-Clutch Test Procedures ....		179
Four Wheel Steer Indexing
Procedure...............................		181
Specifications
Fluid & Lubrication Capacities...		182
Tires	..........................................	183
Weights .....................................		183
Vehicle Dimensions...................		184
Electrical System.......................		185
Engine .......................................		186
Index.............................................		187
Accident Prevention Tags

2003 JLG Industries, Inc.

1

Introduction

The Manual

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

IMPORTANT! Before you operate this vehicle, read this manual completely and carefully so 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 reference to the right side, left side, front, or rear are given from the operator's seat looking in a forward direction.

JLG Industries, Inc. is hereinafter referred to as JLG.

Replacement Parts

For easy reference when ordering replacement parts or making service

inquiries on this vehicle, record its 1 model and serial number on the back

cover of this manual. The serial number is stamped into the serial number plate (1) which is located on the vehicle’s frame.

IMPORTANT! The replacement of any part on this vehicle by anything other than a JLG authorized

replacement part may adversely OH0280 affect the performance, durability or

safety of this vehicle and may void the warranty. JLG assumes no liability for unauthorized replacement parts which adversely affect the performance, durability or safety of this vehicle.

Reports

IMPORTANT! A Warranty Registration form must be filled out by the Sky Trak Distributor, signed by the purchaser, and returned to JLG once the product is sold and/or put into service. This report activates the warranty period, assuring that your claims during the warranty period will be processed promptly. To guarantee full warranty service, make sure your local Sky Trak Distributor has returned the business reply card of this form to JLG.

2	Model 10042 Rev. 11/03

Safety Practices

Disclaimer

JLG reserves the right to make changes on and to add improvements upon its products at any time without public notice or obligation. JLG also reserves the right to discontinue manufacturing any product at its discretion at any time.

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 [phone]. An order form for these kits is available through our website,

http://www.jlg.com.

The information in this manual does not replace any safety rules and laws used in your area. Before operating this vehicle, learn the rules and laws for your area. Make sure the vehicle has the correct equipment according to these rules and laws.

Your safety and the safety of others in the worksite depend significantly upon your knowlege and understanding of all correct operating practices and procedures for this vehicle.

WARNING: DO NOT modify or alter (weld, drill, etc.) any part of this vehicle without consulting JLG. Modifications can weaken the structure creating a hazard that can cause death or serious personal injury.

Hazard Classification System

OP0330

This safety alert symbol is used with the following signal words to attract your attention to messages found within the manual and on hazard decals located on the vehicle. They are reproduced herein and pertain to proper operation and procedure messages contained throughout the manual. The message that follows the symbol contains important information about Safety. To avoid possible death or serious personal injury, carefully read and follow the messages! Be sure to fully understand the potential causes of death or injury.

Model 10042 Rev. 11/03

3

Safety Practices

Signal Word

A signal word is a distinctive word located on hazard decals and used throughout this manual that alerts the viewer to the existence of and relative degree of the hazard.

DANGER:

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

WARNING:

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

CAUTION:

The signal word “CAUTION” indicates a potentially hazardous situation which, if not avoided, may 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, may result in property damage.

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

4	Model 10042 Rev. 11/03

Safety Practices

Accident Prevention Tags

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

3

DANGER

DANGER

1

2

OH3350

New or Additional Operators

At the time of original purchase, the purchaser of this vehicle was instructed by the seller on its proper use. If this vehicle is to be used by an employee or is loaned or rented to someone other than the purchaser, make certain that the new operator is trained, in accordance with the OSHA regulations referenced on page 3, and reads and understands this Operators Manual before operating the vehicle.

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

Model 10042 Rev. 11/03

5

Safety Practices

Instructional Symbols

The following symbol definitions will help you understand all hazard related decals and load charts used on this vehicle.

OP0330

Safety Alert Symbol

OH2100

Read Operator’s Manual

OH2090

Fasten Seat Belt

OH3100

This Symbol Signifies That

Specific Attachments Must

Only Be Used On Vehicles

Equipped With Auxiliary

Hydraulics.

Always Connect Couplers.

6	Model 10042 Rev. 11/03

Safety Practices

Hazard Symbols

OH2110

OH2120

OH2130

-

Lead Acid Batteries

Generate Explosive

Gases

OH2300

Rotating Fan Blades	Vehicle Tipover Can
Can Cut	Crush
OH2150	OH2140

Rotating Belts Can	Electrocution Can		Vehicle Roll Away Can
Cut Or Entangle	Cause Death Or	Cause Death Or Serious
	Serious Injury		Injury
OH3160	OU1450		OH3110

	AVOID CRUSHING,	ENGINE EXPLOSION	Swinging Loads Can
		Can Result In Death	Cause Vehicle Tipover
	Falling Off Vehicle Can
		Or Serious Injury	Which Can Result In
	Cause Death Or Serious
			Death Or Serious Injury
	Injury
		OH2161	OH2721

	FALLING OFF ATTACHMENT Can	VEHICLE TIPOVER, Outriggers
		Over Holes Or Voids Can Cause
	Result In Death Or Serious Injury
		Death Or Serious Injury.

Model 10042 Rev. 11/03

7

Safety Practices

Avoidance Symbols

OH2320

Keep Lit Cigarettes

Away

OH2310

Keep Away From

Rotating Fan Blades

OH2280

Do Not Raise Boom

While On A Slope

OH2330

OU1520

Keep Flames and

Stop Operation At

This Point

Ignition Sources Away

				OU1460
			OU1510	DO NOT Use Ether Or
	Prohibition			Other High Energy
				Starting Aids.
	Symbol. DO NOT
				Engine Equipped With
	Operate
				Grid Heating System.

OH2270	OH2290
Do Not Travel With	Maintain Proper Air
Boom Raised	Pressure In Tire

To Avoid Vehicle Tipover

ALWAYS:

• Travel Slowly

• Rig Properly

• Use Two Tethers

OH3120

8	Model 10042 Rev. 11/03

Safety Practices

Avoidance Symbols (cont’d)

OH2260

Engage Parking Brake

OH2240

Do Not Travel With

Personnel In Work

Platform

OH2220

DO NOT JUMP

•Brace Yourself and Stay With Vehicle

•Keep Seat Belt Fastened

•Hold On Firmly

•Lean Away From The Point Of Impact

OH2250

Keep Clear Of Power

Lines

OH2230

Carry No Riders

OH2170

Use Only Compliant

Work Platforms To

Raise Or Lower

Personnel

OH3170

ALWAYS Fully Lower

Outriggers Onto Solid

Surfaces

Model 10042 Rev. 11/03

9

Safety Practices

Personal Considerations

1. Seat Belt

Always fasten the seat belt before starting the engine.

2. Clothing and Safety Gear

DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts. Wear protective clothing and personal safety gear issued or called for by job conditions.

3. Dismounting

DO NOT get off the vehicle until you:

• level the vehicle,

• ground the carriage,

• place the travel select lever in

(N) NEUTRAL,

• place the neutral lock lever in

(N) NEUTRAL LOCK,

• engage the parking brake

switch,

OH1650

•turn the engine OFF, if appropriate,

•unbuckle the seat belt,

•exit the vehicle using the hand holds.

4.Chemical Hazards

A.Exhaust Fumes

Fumes from the engine exhaust can cause death or serious personal injury. DO NOT operate vehicle in an enclosed area without a ventilation system capable of routing the hazardous fumes outdoors.

B.Explosive Fuel

Engine fuel is flammable and can cause a fire and/or an explosion. Avoid danger by keeping sparks, open flames and smoking materials away from the vehicle and from fuel during refueling or when servicing the fuel system. Know where fire extinguishers are kept on the worksite and how to use them.

10	Model 10042 Rev. 11/03

Safety Practices

C.Ether or High Energy Starting Aids

The engine utilizes a grid heating system inside the induction manifold for cold starting conditions.

WARNING: This diesel engine uses a grid heating system inside the induction manifold. DO NOT use ether or any high energy fuels to assist starting. An explosion may cause death or serious personal injury or engine damage.

DO NOT use ether or any other high energy starting aids during cold starting. An engine explosion can result in death or serious personal injury.

ENGINE EXPLOSION can result in death or serious personal injury.

DO NOT use Ether or other high energy starting aids.

Engine equipped with grid heating system.

4110460

OU1470

D.Hydraulic Fluid

DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin causing death or serious personal injuries.

HOT HYDRAULIC FLUID WILL CAUSE SEVERE BURNS. Wait for fluid to cool down before disconnecting lines.

DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid.

Hydraulic fluid can cause permanent eye injury. Wear appropriate eye protection and stop engine. Relieve pressure before disconnecting lines by moving all joysticks back and forth through all functions.

If anyone is injured by or if any hydraulic fluid is injected into the skin, obtain medical attention immediately or gangrene may result.

Model 10042 Rev. 11/03

11

Safety Practices

E.Batteries

The following WARNING is intended to supplement and does not replace the warnings and information provided on the battery by the battery manufacturer.

When jump starting the vehicle, carefully follow instructions found under “Jump Starting” on page 60.

-

OS0621

Keep sparks, flames and lit smoking materials away from the battery at all times. Lead acid batteries generate explosive gases. Severe chemical burns can result from improper handling of battery electrolyte. Wear safety glasses and proper protective gear when handling batteries to prevent electrolyte from coming in contact with eyes, skin or clothing.

Battery Electrolyte First Aid:

•External Contact — Flush with water.

•Eyes — Flush with water for at least 15 minutes and get medical attention immediately.

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

Get medical attention immediately.

IMPORTANT! In case of internal contact, DO NOT give fluids that would induce vomiting!

12	Model 10042 Rev. 11/03

Safety Practices

5. Moving Parts Hazard

DO NOT place limbs near moving parts. Severing of any body part can result.

Turn OFF engine and wait until fan and belts stop moving before servicing.

MOVING PARTS can cut.

Keep clear of fan and belts while engine is running.

MOVING PARTS can entangle.

OT0810

6. Lowering Boom or Falling Load Hazard

DO NOT get under a raised boom unless it is blocked up safely. Always empty the attachment of any load and block the boom up before doing any servicing that would require the boom to be raised.

NEVER allow anyone to walk or stand under the boom. A lowering boom or falling load can result in death or serious personal injury.

Model 10042 Rev. 11/03

13

Safety Practices

Operational Considerations

1. Preparation and Prevention

Know the location and function of all vehicle controls.

Make sure all persons are away from the vehicle and that the travel select lever is in the (N) NEUTRAL position with the parking brake switch engaged before starting the engine.

Holes, obstructions, debris and other worksite hazards can cause death or serious personal injury. Always walk around and look for these and other hazards before operating the vehicle in a new worksite.

Prevent accidents when you move the vehicle around the worksite. Know the rules for movement of people and vehicles on the worksite. Have a person act as a lookout for you. Follow the instructions of signals and signs.

DO NOT operate the vehicle unless all hazard and instructional decals are in place and readable. (Replace all missing, illegible, or damaged decals.)

2. Clearances

Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you do not have a clear view of conditions that affect clearances. Travel with the boom fully retracted and lowered as far as possible while still maintaining enough ground clearance for conditions.

Always check boom clearances carefully before driving underneath door openings, bridges, etc.

Always check for power lines when raising the boom. Beware of overhead wires. Contact with electrical power lines can result in electrocution. See “Electrocution Hazards” on page 15.

3. Visual Obstruction

Dust, smoke, fog, etc. can decrease vision and cause an accident. Always stop or slow the vehicle until the obstruction clears and the worksite is visible again. Have a lookout person assist you.

Where the load will obstruct the operator’s vision, it is recommended that the vehicle be operated in REVERSE, looking backwards in the direction of travel. Travel at a slower speed and get someone to direct you.

14	Model 10042 Rev. 11/03

Safety Practices

4. Underground Hazards

Know the location of all underground hazards before operating this vehicle in a new area or worksite. Electrical cables, gas and water pipes, sewer, or other underground objects can cause death or serious personal injury. Contact your local underground utility service or diggers hotline to mark all underground hazards.

5. Electrocution Hazards

NEVER operate this vehicle in an area where overhead power lines, overhead or underground cables, or other power sources may exist without first requesting that the appropriate power or utility company deenergize the lines, or take other suitable precautions.

OS0063

Model 10042 Rev. 11/03

15

Safety Practices

6. Elevating Personnel

Use only a compliant work platform meeting the ASME B56.6 standards for lifting and lowering personnel. NEVER transport personnel in a work platform for even the shortest distance.

Death or serious personal injury can occur if these rules are not obeyed. Riders can fall and be crushed or run over. Avoid accidents.

For other specific precautions, see “Elevating Personnel” on page 88.

WARNING	WARNING
AVOID	FALLING OFF ATTACHMENT,
	can result in death or
CRUSHING,	serious injury.
falling off
vehicle can
cause death
or serious
injury

Allow no riders

OH3180

Lift or lower personnel only in a compliant work platform.

DO NOT TRAVEL with personnel in a work platform.

4110389

OU0620

7. Tip Over Hazard

DANGER

VEHICLE	DO NOT	DO NOT raise	MAINTAIN
TIPOVER	travel	boom while	proper tire
can result	with the	on a slope	pressure at
in death or	boom	unless load	all times.
serious injury.	raised.	is level.

OS0086

Traveling with the boom raised is dangerous and can cause tipover. Keep the boom as low as possible. Travel with extreme caution and at the slowest possible speed.

Keep the vehicle under control at all times. When negotiating turns, slow down and turn the steering wheel in a smooth sweeping motion. Avoid jerky turns, starts or stops. Reduce vehicle speed on rough ground and slopes.

16	Model 10042 Rev. 11/03

Safety Practices

DO NOT exceed the rated lift capacity of the vehicle as structural damage and unstable conditions will result.

To ensure that the vehicle is positioned in the most stable condition before operating an attachment, use the frame sway control (frame tilt) to level the vehicle. The vehicle is level when the frame level indicator gauge reaches (0°) zero degrees.

If the vehicle cannot be leveled using the frame sway control, reposition the vehicle.

Frame swaying left or right with the boom raised above horizontal is dangerous. Always use the frame sway control to level the vehicle before raising the boom above horizontal, with or without a load. If the vehicle cannot be leveled using frame sway control, reposition the vehicle.

DANGER

VEHICLE TIPOVER, outriggers	ALWAYS fully lower outriggers
over holes or voids can cause	onto solid surfaces.
death or serious injury.

4107971

OH0801

Lowering outriggers over holes or on soft terrain can compromise the stability of the vehicle which could result in vehicle tipover. For optimum stability, lower the outriggers just far enough until the front of the vehicle starts to raise and maintains a firm footing.

NEVER attempt to move the vehicle after the outriggers have been lowered.

Model 10042 Rev. 11/03

17

Safety Practices

8. Emergency Exit Rear Window

The rear window (1) in the enclosed cab can be used as an emergency exit by removing the latch pin (2) located on the window latch (3). The window is then free to swing open.

2

1.

2.

3.

1

3

OH1730

9. Tire Pressure

DANGER

VEHICLE	DO NOT	DO NOT raise	MAINTAIN
TIPOVER	travel	boom while	proper tire
can result	with the	on a slope	pressure at
in death or	boom	unless load	all times.
serious injury.	raised.	is level.

OS0085

MAINTAIN proper tire pressures at all times. An underpressurized tire(s) adversely affects vehicle stability. If proper tire pressures are not maintained, this vehicle can tip over.

To ensure proper vehicle stability, check all four tire pressures before operating the vehicle.

18	Model 10042 Rev. 11/03

Safety Practices

10.Do Not Jump

DANGER

AVOID CRUSHING if vehicle tips.

Jumping can result in death or serious injury.

•DO NOT JUMP.

•Brace yourself.

• Stay in cab.

• Keep seat belt on.

OH3190

If a vehicle ever becomes unstable and starts to tip over:

•BRACE YOURSELF and STAY WITH THE VEHICLE,

•KEEP YOUR SEAT BELT FASTENED,

•HOLD ON FIRMLY and

•LEAN AWAY FROM THE POINT OF IMPACT.

Indecision and trying to escape from a tipping vehicle can result in death or serious personal injury.

Model 10042 Rev. 11/03

19

Safety Practices

11.Slopes

DO NOT park the vehicle on an incline and leave it unattended.

•Driving across a slope is dangerous, as unexpected changes in the slope can cause tipover. Ascend or descend slopes slowly and with caution.

•Ascend or descend slopes with the heavy end of the vehicle pointing up the slope.

NOTE: The rear of the vehicle is normally considered the heavy end unless the carriage is fully loaded. In this case the front of the vehicle is now the heavy end.

•Unloaded vehicles should be operated on all slopes with the carriage pointing down the slope.

•On all slopes, the load must be tilted back and raised only as far as necessary to clear the ground.

•When operating on a downhill slope, reduce travel speed and downshift to a low gear to permit compression braking by the engine and aid the application of the service brakes.

12.Falling Load Hazard

DO NOT exceed the total rated load capacity of the specific type fork being used. Each fork is stamped with a maximum load capacity. If the capacity is exceeded, forks may break. See “Fork Ratings” on page 87.

DO NOT downshift at a high ground speed. Sudden slowing can cause the load to drop off the forks.

13.Ventilation

Sparks from the electrical system and the engine exhaust can cause an explosion. DO NOT operate this vehicle in an area with flammable dust or vapors unless good ventilation has removed the hazard.

Carbon monoxide fumes from the engine exhaust can cause suffocation in an enclosed area. Good ventilation is very important when operating this vehicle.

20	Model 10042 Rev. 11/03

Safety Practices

Equipment Considerations

WARNING: DO NOT modify or alter (weld, drill, etc.) any part of this vehicle without first consulting JLG. Modifications can weaken the structure creating a hazard that can cause death or serious personal injury.

DO NOT by-pass or disconnect any electrical or hydraulic circuits. Consult the JLG Service Department or your local Sky Trak Distributor if any circuit is malfunctioning.

DO check for frayed or cut seat belt webbing, damaged buckles or loose mounting brackets. Replace immediately if required.

ALWAYS wear a seat belt when operating the vehicle.

DO check tire pressure on all four tires. Add air if required.

DO check the condition of all four rims. Check for bent flanges and/or bead mounting areas.

DO check the parking brake/transmission de-clutch operation. Refer to the test procedures on page 179. Repair immediately if required.

DO keep all non-skid surfaces clean and free of debris. Replace if worn, damaged or missing.

DO check the condition of decals. Replace decals if missing, damaged or illegible. The following pages show the proper location of the decals.

Model 10042 Rev. 11/03

21

Safety Practices

3

		7
	2
	1. Read operator's manual	3. Allow no riders.
	before operating.
	2. Fasten seat belt.	4. Use a compliant
		work platform to lift
		or lower personnel.

5

6

DANGER

AVOID CRUSHING if vehicle tips.

Jumping can result in death or serious injury.

•DO NOT JUMP.

•Brace yourself.

• Stay in cab.

• Keep seat belt on.

WARNING

AVOID

CRUSHING, falling off vehicle can cause death or serious injury

4

DANGER

VEHICLE TIPOVER, outriggers	ALWAYS fully lower outriggers
over holes or voids can cause	onto solid surfaces.

	death or serious injury.
	1
Allow no riders	OH2733
	4107971

8

Item	Part Number	Quantity	Decal Description
1	4110188	1	No Riders Warning
2	4110188	1	Vehicle Rollaway Warning
3	4108991	1	Electrocution Danger
4	7301677	1	Load Chart Booklet
5	4110137	1	Tipover danger
6	4110187	1	Do Not Jump Danger
7	4110188	1	Safety Instructions
8	4107971	1	Outrigger Over Holes Danger

22	Model 10042 Rev. 11/03

Safety Practices

ENGINE EXPLOSION can result in death or serious personal injury.

DO NOT use Ether or other high energy starting aids.

15

Engine equipped with grid heating system.

10

WARNING

FALLING OFF ATTACHMENT, can result in death or serious injury.

			14
	Lift or lower personnel		13
		DO NOT TRAVEL
	only in a compliant	with personnel in
	work platform.	a work platform.
	11
			12
	9
			OH1754
Item	Part Number Quantity		Decal Description
9	4110184	2	Moving Parts Warning
10	4110172	1	Explosive Gases Warning
11	4110389	1	Carrying Personnel Warning
12	4107442	1	Boom Extend Letters
13	4105262	1	Boom Angle Indicator
14	4109791	1	Emergency Exit (Enclosed Cab Only)
15	4110460	2	Ether Starting Warning

Model 10042 Rev. 11/03

23

Operation

Operator Controls

Accelerator Pedal

Pressing down the accelerator pedal (1) increases engine and hydraulic speed of the vehicle. The pedal is spring-loaded to return to idle speed.

NOTE: The accelerator pedal is also used to activate the Cummins ECM Diagnostic system. With the ignition switch in the RUN position, depress and release the pedal three times to activate the system.

Service Brake Pedal

Pressing down the brake pedal (2) decreases the speed of the vehicle by applying the service brakes located in the axles. In the event of engine power loss, the service brake pedal can also be used for braking. It also activates and locks the rear axle to frame lock system when boom angles are greater than 40°, as long as the pedal is depressed.

Steering Wheel

Turning the steering wheel (3) to the left or right steers the vehicle in the corresponding direction. Any one of the steering modes are selectable. Refer to “Steering Select Switch” on page 26.

Horn Button

Pressing the button (4) sounds the horn.

4

3

1

2

MA8560

24	Model 10042 Rev. 11/03

Operation

Ignition Switch

Using the ignition switch key (5), the switch may be turned clockwise from the OFF (6) position to the RUN (7) and START (8) positions. The START position is spring-loaded to return to the RUN position and must be manually held in place for starting.

OFF position (6) — The entire electrical system is shut down.

RUN position (7) — All controls and indicators are operable.

START position (8) — Engages starter motor to crank the engine when the parking brake switch is engaged and the transmission is in NEUTRAL.

6 7

8

5

OT0680

Model 10042 Rev. 11/03

25

Operation

Steering Select Switch

This vehicle has one steering select switch (1) with three positions. The switch is located in the lower switch bank (2) on right side dash panel.

Refer to “Steering Modes” on page 68 for detailed information.

	2
1	OH3240

26	Model 10042 Rev. 11/03

Operation

Park Brake Switch

The Parking Brake Switch (3) has two positions:

P	ENGAGED ............	toggle switch downward
OS0121 P	DISENGAGED............	toggle switch upward	OS1323

The Parking Brake Switch (3) must be ENGAGED to permit engine starting. A red LED, on the parking brake switch, and a light in the instrument cluster will indicate the brake is ENGAGED.

The parking brake may be used to stop in an EMERGENCY situation. However, use caution because the stop will be abrupt and the operator and the load may be jolted forward unexpectedly.

With boom angles greater than 40°, this switch activates the locked mode of the Stabil-TRAK system.

3

OH3240

Model 10042 Rev. 11/03

27

Operation

Neutral Lock Lever

The Travel Select Lever (1) is equipped with a neutral lock. The Neutral Lock Lever (2) locks the Travel Select Lever in NEUTRAL or unlocks the Travel Select Lever so that it can be moved into the FORWARD or REVERSE drive position.

	2
1	N D
	OH3250

To lock the Travel Select Lever (1) in the NEUTRAL position, place the lever in the NEUTRAL position and move the Neutral Lock Lever (2) to the (N) NEUTRAL LOCK position.

To unlock, move the Neutral Lock Lever to the (D) DRIVE position.

N = NEUTRAL LOCK ..................

all the way LEFT

OT0570

D = DRIVE ...................................

all the way RIGHT

OT0580

28	Model 10042 Rev. 11/03