SkyTrak 8042 Operation Manual

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OWNERS/OPERATORS

MANUAL

Model 8042

(S/N 18991 thru 19984

and S/N 0160002332 thru 0160029584)

OH2882

Keep this manual with the vehicle at all times.

Printed in U.S.A. 2/07

8990500 C

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 ..........20

Operation

Operator Controls........................23

Instruments and Indicators..........34

Optional Controls.........................44

Pre-Operation Inspection.............54

Normal Starting............................55

Cold Starting................................56

Jump Starting ..............................57

Refueling .....................................58

Stabil-TRAK System....................60

Operating.....................................63

Using The Capacity Chart ...........72

Fork Ratings ................................81

How To Pick, Carry & Place A

Load..........................................82

Elevating Personnel.....................82

Using Other Attachments ............87

Shut-Off .......................................88

Emergency Operations

Towing A Disabled Vehicle..........89

Emergency Boom Lowering ........91

General Maintenance

General Maintenance................104

Maintenance Schedule And

Checklist.................................105

1. Lubrication Points..............110

2. Air Cleaner And Restriction

Indicator.............................112

3. Engine Cooling System .....116

4. Engine Oil And Filter.........119

5. Engine Fuel System..........123

6. Engine Fan Belt.................128

7. Hydraulic Oil and Filter......129

8. Transmission Oil and

Filter ..................................133

9. Axle Oil..............................136

10. Brake Disk Inspection .......138

11. Wheel End Oil ...................142

12. Wheels and Tires ..............144

13. Batteries............................146

14. Fuse and Relay

Replacement.....................148

15. Boom Chains and Wear

Pads..................................152

Storage and Transport ..............167

Storage......................................167

Transport...................................168

Test Procedures

Stabil-TRAK System Test..........169

Parking Brake/Transmission

De-Clutch Test Procedures....173

Four Wheel Steer Indexing

Procedure...............................175

Specifications

Fluid & Lubrication Capacities...176

Tires ..........................................177

Weights .....................................178

Vehicle Dimensions...................178

Electrical System.......................179

Engine.......................................180

Index.............................................181

Accident Prevention Tags

ã 2003 JLG Industries, Inc.

Introduction

The Manual

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

IMPORTANT! Before 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.

you operate this vehicle, read this manual completely

Replacement Parts

For easy reference when ordering replacement parts or making service inquiries on this vehicle, record its 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 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.

OH0280

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

Sky Trak Distributor has returned the business reply card of this form to JLG.

Model 8042 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 (414) 466-6060. 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 8042 Rev. 11/03

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.

Model 8042 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.

DANGER

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 8042 Rev. 11/03

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.

Model 8042 Rev. 11/03

Hazard Symbols

Safety Practices

OH2110

Lead Acid Batteries Generate Explosive

Gases

OH2300

Rotating Belts Can Cut

Or Entangle

OH2120

Rotating Fan Blades

Can Cut

OH2150

Electrocution Can

Cause Death Or

Serious Injury

OH3160

OH2130

Vehicle Tipover Can

Crush

OH2140

Vehicle Roll Away Can

Cause Death Or Serious

Injury

OH3110

AVOID CRUSHING, Falling Off

Vehicle Can Cause Death Or

Serious Injury

FALLING OFF ATTACHMENT Can

Result In Death Or Serious Injury

Model 8042 Rev. 11/03

OH2161

Swinging Loads Can Cause

Vehicle Tipover Which Can Result

In Death Or Serious Injury

OU1450

ENGINE EXPLOSION

Can Result In Death Or

Serious Injury

Safety Practices

Avoidance Symbols

OH2320 OH2330

Keep Lit Cigarettes

Away

OH2310 OH2270

Keep Away From

Rotating Fan Blades

OH2280

Do Not Raise Boom

While On A Slope

Keep Flames and

Ignition Sources Away

OU1520

Stop Operation At

This Point

OU1510

Prohibition

Symbol. DO NOT

Operate

Do Not Travel With

Boom Raised

OH2290

Maintain Proper Air

Pressure In Tire

To Avoid Vehicle Tipover ALWAYS:

•Travel Slowly

• Rig Properly

• Use Two Tethers

OH3120

Model 8042 Rev. 11/03

Safety Practices

Avoidance Symbols (cont’d)

OH2260 OH2250

Engage Parking Brake

Do Not Travel With

Personnel In Work

Platform

OU1460

DO NOT Use Ether Or

Other High Energy

Starting Aids.

Engine Equipped With

Grid Heating System.

Keep Clear Of Power

Lines

OH2240 OH2230

Carry No Riders

OH2170

Use Only Compliant Work

Platforms To Raise Or Lower

Personnel

DO NOT JUMP

• Brace Yourself and Stay With Vehicle

• Keep Seat Belt Fastened

• Hold On Firmly

• Lean Away From The Point

OH2220

Of Impact

Model 8042 Rev. 11/03

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,

• 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.

OH1650

Model 8042 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.

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.

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

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 8042 Rev. 11/03

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 57.

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.

OS0621

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!

Model 8042 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 8042 Rev. 11/03

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.

Model 8042 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 8042 Rev. 11/03

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 82.

WARNING

CRUSHING,

falling off

vehicle can

cause death

or serious

Allow no riders

AVOID

injury

OH3180

WARNING

FALLING OFF ATTACHMENT,

Lift or lower personnel only in a compliant work platform.

can result in death or

serious injury.

DO NOT TRAVEL with personnel in a work platform.

4110389

OU0620

Model 8042 Rev. 11/03

Safety Practices

7. Tip Over Hazard

DANGER

VEHICLE TIPOVER can result in death or serious injury.

DO NOT travel with the boom raised.

DO NOT raise boom while on a slope unless load is level.

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

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.

MAINTAIN proper tire pressure at all times.

and at

OS0086

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.

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.

Model 8042 Rev. 11/03

109 7

OH1730

Safety Practices

9. Tire Pressure

DANGER

VEHICLE TIPOVER can result in death or serious injury.

DO NOT travel with the boom raised.

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.

10.Do Not Jump

DANGER

AVOID CRUSHING

if vehicle tips.

Jumping can

result in death

or serious

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

injury.

DO NOT raise boom while on a slope unless load is level.

OH3190

MAINTAIN proper tire pressure at all times.

OS0085

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 8042 Rev. 11/03

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

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

• 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.

the slope.

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 81.

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.

Model 8042 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 173. 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 8042 Rev. 11/03

Safety Practices

WARNING

AVOID

CRUSHING,

falling off

vehicle can

cause death

or serious

injury

1. Read operator's manual before operating.

2. Fasten seat belt.

3. Allow no riders.

4. Use a compliant work platform to lift or lower personnel.

Allow no riders

Item Part Number Quantity Decal Description

1 2 4110188 1 Vehicle Rollaway Warning 3 4108991 1 Electrocution Danger 4 7301676 1 Load Chart Booklet 5 4110137 1 Tipover danger 6 4110187 1 Do Not Jump Danger 7 4110188 1 Safety Instructions

4110188 1 No Riders Warning

DANGER

AVOID CRUSHING

if vehicle tips.

Jumping can

result in death

or serious

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

OH17431

injury.

Model 8042 Rev. 11/03

Safety Practices

Lift or lower personnel only in a compliant work platform.

WARNING

FALLING OFF ATTACHMENT,

can result in death or

serious injury.

DO NOT TRAVEL with personnel in a work platform.

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

4110389

Item Part Number Quantity Decal Description

1 2 4110172 1 Explosive Gases Warning

3 4110389 1 Carrying Personnel Warning 4 4107442 1 Boom Extend Letters 5 4105262 1 Boom Angle Indicator 6 4109791 1 Emergency Exit (Enclosed Cab Only) 7 4110460 2 Ether Starting Warning

4110184 2 Moving Parts Warning

Model 8042 Rev. 11/03

OH2894

Operation

Operator Controls

Accelerator Pedal

Pressing down the accelerator pedal (8) 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 (9) 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 (10) 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 25.

Horn Button

Pressing the button (11) sounds the horn.

Model 8042 Rev. 11/03

MA8560

Operation

Ignition Switch

Using the ignition switch key (1), the switch may be turned clockwise from the OFF (2) position to the RUN (3) and START (4) positions. The START position is spring-loaded to return to the RUN position and must be manually held in place for starting.

OFF position (2) — The entire electrical system is shut down. RUN position (3) — All controls and indicators are operable. START position (4) — Engages starter motor to crank the engine when the

parking brake switch is engaged and the transmission is in NEUTRAL.

OT0680

Model 8042 Rev. 11/03

Operation

Steering Select Switch

This vehicle has one steering select switch (5) with three positions. The switch is located in the lower switch bank (6) on right side dash panel.

Refer to “Steering Modes” on page 65 for detailed information.

Model 8042 Rev. 11/03

OH3240

Operation

Park Brake Switch

The Parking Brake Switch (1) has two positions:

ENGAGED............ toggle switch downward

OS0121

DISENGAGED........... toggle switch upward

OS1323

The Parking Brake Switch (1) 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.

OH3240

Model 8042 Rev. 11/03

Operation

N D

Neutral Lock Lever

The Travel Select Lever (2) is equipped with a neutral lock. The Neutral Lock Lever (3) 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.

OH3250

To lock the Travel Select Lever (2) in the NEUTRAL position, place the lever in the NEUTRAL position and move the Neutral Lock Lever (3) 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

Model 8042 Rev. 11/03

Operation

Travel Select Lever

The Travel Select Lever (1) has three positions to select direction of travel:

F = FORWARD (2)..........all the way FORWARD

N = NEUTRAL (3)...........CENTER position

R = REVERSE (4) .......... all the way REARWARD

OS0340

OH3260

To change travel selections, move the lever FORWARD or REARWARD to the desired selection.

When the Travel Select Lever is shifted to REVERSE, the back-up alarm will automatically sound.

NOTE: The Travel Select Lever must be in the (N) NEUTRAL position to permit engine starting and when boom angles are greater than 40°, shifting into NEUTRAL activates the locked mode of the Stabil-TRAK system.

Model 8042 Rev. 11/03

Operation

Gear Select Lever

The Gear Select Lever (5) has a twist grip handle with four positions. Vehicles have four forward gears and three reverse gears.

OH3270

Use first gear for highest torque and pulling power. Use higher gears for higher ground speed. The recommendations listed in the table that follows are guidelines only. Always use good judgement when traveling with a load.

Recommended Gear/Speed for Various Load/Travel Conditions

Load Size Surface Gear Speed

No Load Smooth 4th* 0 to 20 mph (0 to 32 km/h)

Improved 3rd 0 to 14 mph (0 to 23 km/h)

Rough 2nd 0 to 6 mph (0 to 9,7 km/h)

Load Smooth 3rd 0 to 14 mph (0 to 23 km/h)

up to 4,500 lbs Improved 2nd 0 to 6 mph (0 to 9,7 km/h)

(up to 2.041 kg)

Load Smooth 3rd 0 to 14 mph (0 to 23 km/h)

4,500 to 8,000 lbs Improved 2nd 0 to 6 mph (0 to 9,7 km/h)

(2.041 to 3.629 kg)

Rough 2nd 0 to 6 mph (0 to 9,7 km/h)

Rough 1st 0 to 3.5 mph (0 to 5,6 km/h)

*NEVER travel in 4th gear when carrying a load.

Model 8042 Rev. 11/03

Operation

Boom Control Lever

The boom control lever (1) is a joystick with variable motion from the center to control the boom functions:

Boom Lift .............................move lever backward

Boom Lower ........................move lever forward

Boom Extend....................... move lever to the right

OH0170

Boom Retract ...................... move lever to the left

Two boom functions can be accomplished at the same time by moving the lever into the proper quadrant. For example: moving the lever forward and to the left will lower and retract the boom simultaneously.

The speed of the function depends directly upon the amount of lever travel in the corresponding direction. Increasing the engine speed will also increase the function speed.

OH2900

Model 8042 Rev. 11/03

Operation

Attachment Tilt and Frame Sway Control Lever

The attachment tilt and frame sway control is a joystick (2) with four perpendicular motions from the center to control two attachment tilt functions and two frame sway functions:

Frame Sway Left ................. move lever to the left

Frame Sway Right............... move lever to the right

Attachment Tilt Down...........move lever forward

OH0410

Attachment Tilt Up ...............move lever backward

The attachment is self leveling and will retain any set angle throughout boom lifting, lowering, retracting or extending operations.

OH2900

Model 8042 Rev. 11/03

Operation

Seat Belt

WARNING: Death or serious personal injury may result

from failure to wear the seat belt installed on this vehicle. The seat belt is a critical component of the Operator’s protective Structure, and is provided for the operator’s protection in case of vehicle upset. The seat belt MUST be worn whenever this vehicle is operated.

IMPORTANT! Inspect the seat belt every time it is used, looking for cut or worn webbing, or any defect in the latch assembly. If any wear or damage is noted, DO NOT operate the vehicle until the seat belt is replaced.

Before the engine is started, adjust the seat as required for position and comfort. Then adjust the seat belt as follows:

1. Grasp both free ends of the belt and make certain that the belt webbing is not twisted or entangled in any portion of the seat assembly.

2. With your back straight in the seat, couple the retractable end or the male end of the belt into the receptacle (buckle) end of the belt.

3. With the belt buckle as low on your body as possible, pull the retractable end of the belt or the free end of the belt away from the buckle until it is tight across the lap.

STANDARD 2 INCH WIDE

SEAT BELT

4. To release the belt latch, depress the red button (1) or lift the black cover (2) of the buckle (dependant on belt style installed), and pull the free end (3) from the buckle.

An optional 3 inch wide seat belt is available for those locations that require a 3 inch seat belt.

OPTIONAL 3 INCH WIDE

SEAT BELT

Model 8042 Rev. 11/03

OL0430

Operator’s Seat Adjustment

The operator’s seat can be adjusted three ways:

A. Fore and Aft Adjustment

Pull the handle (4) outward to adjust the seats forward and backward. Release the handle to lock the seat in the desired position.

B. Suspension Adjustment

Turn the knob (5) on the front of the seat (6) to adjust the suspension to correspond with the operator’s weight. Turn clockwise to increase stiffness. Turn counter-clockwise to reduce the stiffness.

C. Backrest Angle Adjustment

The angle of the seat backrest can be adjusted to suit the operator. Move the lever (7) located on the left side of the seat backrest (8) to adjust the angle.

Operation

Model 8042 Rev. 11/03

OH1820

Operation

Instruments and Indicators

Hourmeter

OS0260

The hourmeter (1) records engine operating hours and has a total readout of 9,999.99 hours. It is located at the lower portion of the instrument cluster (2) on the right side console.

Fuel Gauge

OH2470

The fuel gauge (3) indicates the quantity of fuel in the fuel tank. The gauge is located in the center of the instrument cluster (2) on the right side console. Capacity of the fuel tank is 37 gallons (140 liters) total capacity with a usable capacity of 35.6 gallons (135 liters).

0000 00

Model 8042 Rev. 11/03

OH1810

Operation

Instrument Cluster Light Test

Test the bulbs in the instrument cluster before starting the engine. Turn the ignition switch to the RUN position, ALL nine lights in the

instrument cluster will come ON for a few seconds and then go out. Replace any bulbs that DO NOT come ON during this test. These lights will warn the operator if an abnormal condition should arise during operation and will also inform the operator when the Stabil-TRAK system is active, road lights are on high beam or the turn signals are activated.

(4)

(5) (6)

(7) (8)

(9) (10)

(11) (12)

Position of corresponding lights:

• Alternator Charging Light (4)

• Park Brake Light (5)

• Engine Oil Pressure Light (6)

• Engine Coolant Temperature Light (7)

• Hydraulic Tank Temperature Light (8)

• Transmission Temperature Light (9)

• High Beam Light (10)

• Stabil-TRAK Light (11)

• Turn Signal Light (12)

0000 00

OH1810

Model 8042 Rev. 11/03

Operation

Function Indicator Lights

A. Stabil-TRAK Indicator Light

OH2500

The Stabil-TRAK light (1) will come ON when the system has been activated. The rear axle will lock when one or more of the following conditions exist with the boom above a 40° angle.

• Parking Brake Switch engaged

• Travel select lever in (N) NEUTRAL

• Service brake pedal depressed and held

With the boom above a 40° angle and traveling in a forward or reverse drive gear, the Stabil-TRAK Light (1) will go OFF. In this condition the rear axle is unlocked and is allowed to pivot, but will respond slowly changes in terrain.

ALWAYS be sure the Stabil-TRAK system is functioning properly when operating vehicle. Refer to “Understanding the Stabil-TRAK System” later in this manual for a detailed explanation of this system.

DANGER: Vehicle tipover can result in death or serious

injury. Traveling with the boom raised is dangerous and can cause vehicle tipover. Keep the load as low as possible. Travel with extreme caution

and at the slowest possible speed.

0000 00

OH1810

Model 8042 Rev. 11/03

B. Park Brake Light

Operation

OH2480

The park brake light (2) illuminates any time the park brake is applied and the ignition switch is in the RUN position.

C. High Beam Light

(used with optional road light package only)

The high beam light (3) illuminates when the road option headlights are on full (high) beam and will turn OFF when the headlights are switched to low beam.

OH2490

D. Turn Signal Light

(used with optional road light package only)

The turn signal light (4) will illuminate and flash when the road option turn signals are activated in either direction or when the road option hazard lights are activated.

OH2510

Model 8042 Rev. 11/03

0000 00

OH1810

Operation

Warning Indicator Lights

There are five additional indicator lights in the instrument cluster that will illuminate during critical circumstances. All five warning indicator lights demand immediate attention and vehicle servicing. In many cases, the vehicle should be shut down AS SOON AS PRACTICAL mechanical failure.

The five warning indicator lights are:

A. Engine Coolant Temperature Warning Indicator Light

OH2520

The engine coolant temperature warning light (1) illuminates when the engine coolant temperature is too high; above 210° F (99° C). SHUT THE VEHICLE DOWN AS SOON AS PRACTICAL.

B. Transmission Temperature Warning Indicator Light

OH2530

to prevent serious

The transmission temperature warning light (2) illuminates when the transmission oil temperature is too high; above 250° F (121° C). Stop and idle the vehicle in NEUTRAL, allowing time for cooling. If the light does not go out after two minutes, shut the vehicle down.

C. Hydraulic Oil Temperature Warning Indicator Light

OH2540

The hydraulic oil temperature warning light (3) illuminates when the hydraulic oil temperature is too high; above 195° F (91° C). Stop and idle the engine, allowing time for cooling. If the light does not go out after five minutes, shut the vehicle down.

Model 8042 Rev. 11/03

Operation

0000 00

D. Engine Oil Pressure Warning Indicator Light

OH2550

The engine oil pressure warning indicator light (4) will come ON during engine start-up and go OUT once the engine has started. This is normal. If the light comes ON while the engine is running, this indicates that the engine oil pressure is too low. SHUT THE VEHICLE DOWN AS SOON AS PRACTICAL.

E. Alternator Charging Warning Indicator Light

OH2560

The alternator charging warning light (5) illuminates when the charging system is not working properly. Service the engine alternator.

OH1810

Model 8042 Rev. 11/03

Operation

Function Indicator Lights

There are two additional indicator lights located on the right side of the front dash:

A. Engine Air-Intake Heater Indicator

OU0040

The engine air-intake heater indicator light (1) located in the upper switch bank on the right side of the front dash. This light illuminates, with the ignition switch in the RUN position, any time the ambient temperature drops below 40° F (4° C). The engine grid heater then becomes active and the engine should not be cranked until the light goes OFF. Once the light goes OFF it indicates that the grid heater is at the proper temperature and the engine is ready to start.

NOTE: This indicator light may come ON when the engine is running to indicate that the post heat function is active. This is a normal condition when ambient temperatures are below 40° F (4° C).

Model 8042 Rev. 11/03

OH3280

B. Engine Function Indicator Lights

The engine function indicator lights (2) are located in the upper switch bank on the right side of the front dash. The light indicates any faults that arise in the engine during operation. The light contains a RED light (3) and a AMBER light (4).

If the RED light (3) comes ON during operation, STOP IMMEDIATELY and diagnose the fault by activating the ECM diagnostic system. Activate the system with the accelerator pedal.

Activate the system and read the code as indicated by the RED light. Contact your local Cummins dealer for an explanation of these codes or refer to the Cummins Engine Owners Manual or call the Cummins Customer Assistance Center at 1-800-343-7357.

If the AMBER light (4) comes ON during operation, the engine diagnostic system has detected a fault within the engine. Stop the engine and diagnose the fault by activating the ECM diagnostic system.

Activate the system and read the code as indicated by the light. Contact your local Cummins dealer for an explanation of these codes or refer to the Cummins Engine Owners Manual or call the Cummins Customer Assistance Center at 1-800-343-7357.

Cummins ECM Diagnostic System Activation

Operation

OH3290

the engine

With the engine OFF, turn the ignition switch to the RUN position. DO NOT start the engine.

Completely depress and release the accelerator pedal three times. This will activate the system, both the AMBER light and RED light will come ON momentarily and then both will begin to flash the code. If the system has been activated with the accelerator pedal and no faults are present, both the AMBER light and the RED light will come ON and stay ON.

ECM Light Code Identification

The AMBER light will flash one time to identify the start of the code followed by a one or two second pause. Then the RED light will flash the code sequence, pausing for one or two seconds between numbers. The AMBER light will flash once after the RED light has flashed the code to signify the end of that fault code.

Model 8042 Rev. 11/03

Operation

Frame Level Indicator

The indicator (1) is mounted on the top inside of the Operator's Protective Structure (cab). This is a bubble type indicator which allows the operator to tell if the vehicle has been positioned in a level condition. Always frame sway the vehicle either right or left until the indicator reads zero degrees (0°). If zero cannot be achieved, then reposition the vehicle until it is level before placing the load.

NOTE: Maximum frame sway is 10° in either direction.

OS0232

Boom Angle Indicator

The boom angle indicator is a plumb arrow (2) with angular graduations (3) from minus 10° to plus 80°. It is located on the left side of the boom and is visible from the operator’s position. Use this indicator to determine the boom angle when reading the capacity chart (see “Using The Capacity Chart”).

4105262

OH0302

Model 8042 Rev. 11/03

Operation

Rear View Mirrors

Two rear view mirrors are provided to aid the operator's rear vision. A rectangular flat lens mirror (4) is mounted on the upper left of the cab. A convex lens mirror (5) is mounted on the right side of the frame. Both mirrors are adjustable to obtain the best rear view by the operator.

OH1830

Model 8042 Rev. 11/03

Operation

Optional Controls

Auxiliary Attachment Control Lever

The auxiliary attachment control lever (1) controls the functions of an optional attachment that is mounted to the vehicle and requires a hydraulic supply for operation. Some of the optional attachments that require auxiliary hydraulics are: Side Tilt Carriage, Swing Carriage, Auger, and 3 Foot Truss Boom w/Winch.

When the control lever is moved to the right

it will provide hydraulic system pressure through the female disconnect coupling for the auxiliary attachment. Hydraulic fluid will return

OH0431

to the tank through the male disconnect coupling. When the control lever is moved to the left it will provide

hydraulic system pressure to the male disconnect coupling for the auxiliary attachment. Hydraulic fluid will return to the tank

OH0451

through the female disconnect coupling.

The control lever will provide the following typical functions for each specific attachment if they are connected properly. Operation will be reversed if incorrectly connected. We recommend reversing the disconnect couplings on the hoses that are supplied with the attachment if operation is reversed.

Side Tilt Carriage Operation:

• Control Lever right ..................... tilt right

• Control Lever left ....................... tilt left

Swing Carriage Operation:

• Control Lever right ..................... swing right

• Control Lever left ....................... swing left

Auger Operation:

• Control Lever right ..................... auger dig

• Control Lever left ....................... auger retract

3 Foot Truss Boom w/Winch Operation:

• Control Lever right ..................... cable extends

• Control Lever left ....................... cable retracts

OH2910

Model 8042 Rev. 11/03

Operation

Worklight Switch (Front, Rear & Boom Worklights)

OH2570

This three position rocker switch (2) controls the front, rear and boom worklights. The switch is located in the upper switch bank on the right side dash panel. These lights will only operate when the ignition switch is in the RUN position.

• Push the top of the switch in to turn all the

worklights OFF.

• To turn the front and boom worklight ON,

position the rocker switch to the center position.

OH2591

OH2601

• Push the bottom of the switch in to turn all the

worklights ON.

OH2611

OH3300

Model 8042 Rev. 11/03

Operation

Beacon Light Switch

OH2580

This rocker switch (1) turns the beacon light ON and OFF. The switch is located in the lower switch bank on the right side dash panel. This light will only operate when the ignition switch is in the RUN position.

• Push the bottom of the switch in to turn the

beacon light ON.

• Push the top of the switch in to turn the

beacon light OFF.

OH2611

OH2591

OH3310

Model 8042 Rev. 11/03

Operation

Worklight Switch (with Optional Road Lights)

OH2620

This rocker switch (2) activates the worklight system. The switch is located in the upper switch bank on the right side dash panel. This system will only operate when the ignition switch is in the RUN position. See “Parking Lights, Headlights & High/Low Beam Switch” on page 49 for operation of the road lights.

• Push the top of the switch IN to

DEACTIVATE the entire the worklight system.

• To ACTIVATE the boom worklight

position the rocker switch to the center position.

OH2591

OH2601

• Push the bottom of the switch IN to

ACTIVATE the boom worklight and rear worklights.

OH2611

OH3320

Model 8042 Rev. 11/03

Operation

Emergency Flashers

OS1920

This switch (1) is located in the upper switch bank on the right side dash panel.

• To ACTIVATE the emergency flashers, push

the bottom of the switch IN.

• To DEACTIVATE the emergency flashers

push the top of the switch IN.

OH2611

OH2591

OH3320

Model 8042 Rev. 11/03

Operation

Turn Signals

OH2510

The directional signals are ACTIVATED from the lever (2) on the right side of the steering wheel and will only operate when the ignition switch is in the RUN position.

To activate the left turn signal (3), raise the lever. To activate the right turn signal (4), lower the lever. To deactivate either directional signal, the lever must be manually returned to the center position. The lever will not cancel automatically after a turn.

Parking Lights, Headlights & High/Low Beam Switch

With the ignition switch in the RUN position use the turn signal switch to control the high/low beam headlights, turn on the parking lights and the headlights. Turn the twist grip end of the turn signal switch counterclockwise to the first position (5) to turn the parking lights ON. Turn the twist grip to the second position (6) to turn the headlights and parking lights ON. Turn the twist grip clockwise to the OFF position (7) to turn all the lights OFF. Pull the turn signal switch toward you to switch from low beam to high beam. When the high beam is ON the high beam indicator light will illuminate.

Model 8042 Rev. 11/03

OH3330

Operation

Windshield Wiper Control

OS1930

This three position rocker switch (1) controls the speed of the windshield wiper. This switch is located in the lower switch bank on the right side dash panel.

• To STOP the windshield wiper, push

the top of the switch IN.

• To OPERATE the windshield wiper at

LOW speed, position the switch in the CENTER POSITION.

• To OPERATE the windshield wiper at

HIGH speed, push the bottom of the switch IN.

OH2591

OH2601

OH2611

Model 8042 Rev. 11/03

OH3310

Operation

Skylight Wiper Control

OH1900

This rocker switch (2) turns the skylight wiper ON and OFF. This switch is located in the lower switch bank on the right side dash panel.

• Push the bottom of the switch IN to turn the

skylight wiper ON.

OH2611

• Push the top of the switch IN to turn the

skylight wiper OFF.

OH2591

Windshield & Skylight Washer Control

OS1940

This rocker switch (3) is spring loaded to return to the OFF position when released. This switch is located in the lower switch bank on on the right side dash panel.

• Pressing down on the bottom of the switch

will dispense washer fluid to the windshield and skylight wiper at the same time. The switch must be held in place to activate the washer control.

• Release the switch to deactivate the washer

control.

OH1910

OH2611

OH2591

Model 8042 Rev. 11/03

Operation

Cab Heater & Fan Control

OS1950

The cab heater controls (1) are located directly below the switch banks on the right side dash panel. The control panel consists of: a variable speed fan control knob (2) and a temperature control knob (3).

Control of air flow to the windshield is made by opening, closing or redirecting the air vent louver on the front dash. The cab is heated by the heater unit positioned under the operators seat.

To heat the cab:

OS1950

• Turn temperature control knob (3) to far right position

(RED = HOT),

• Direct desired air flow by adjusting vent louvers,

• Turn fan control (2) to “3” (4) to assure rapid warm-up.

To defrost the cab:

OA1390

• Turn temperature control knob (3) to the far right position

(RED = HOT),

• Direct desired air flow by adjusting vent louver,

• Turn fan control (2) to “3” (4) to assure rapid defrost.

Model 8042 Rev. 11/03

OH3340

Operation

Rear Window Latch

The rear window (5) can be partially opened and secured in place with the rear window latch (6). To open the window, grab the latch handle and pull up and then push the window outward. To close and secure the window, pull the latch handle forward and down.

NOTE: In an emergency situation, the operator can exit through the rear window opening by removing the latch pin (7) on the window latch. The window is then free to swing open.

1 09 7

OH1730

Door Latches

(not pictured) There are two door latches. The outside latch is a key lockable pull-to-

release type. The inside latch is also a pull-to-release latch.

Door Window Latch

(not pictured) The door window can be swung open by releasing the window from inside

the cab. Swing the window all the way open and lock in place on the outside of the cab. To release the window from the open position, push up the release on the lower side of the outside hold or release using the release on the side wall of the cab below the left side window.

Model 8042 Rev. 11/03

Operation

Pre-Operation Inspection

1. Check safety belt for damage. Check for frayed or cut seat belt webbing, damaged buckles or loose mounting brackets. Make any necessary repairs before operating the vehicle.

2. Check all four tires and rims for damage. Check for proper tire pressure, add air if required. Observe the condition of each tire looking specifically for punctures, cracks, cuts, gouges, bulges or any other damage. Check the condition of each rim for bent flanges or any other damage. Make any necessary repairs before operating the vehicle.

3. Check and add engine oil if required. This procedure is explained in greater detail on page 119.

4. Check and add transmission oil if required. This procedure is explained in greater detail on page 133.

5. Check the cooling system overflow bottle for coolant. Add coolant if required. This procedure is explained in greater detail on page 116. Remove any debris blocking the radiator cooling fins.

6. Check the hydraulic oil level sight glass and add hydraulic oil if required. This procedure is explained in greater detail on page 130.

7. Walk around the vehicle and check for oil leakage as well as damaged or missing parts. Make any necessary repairs before operating the vehicle.

Model 8042 Rev. 11/03

Operation

Normal Starting

1. Enter the cab using the hand holds and adjust the seat for comfortable operation.

2. Adjust the mirrors to obtain the best rear view from the operator’s position.

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.

3. Fasten the seat belt.

4. Make sure the parking brake switch is ENGAGED.

5. Place the travel select lever in (N) NEUTRAL and move the neutral lock lever to NEUTRAL LOCK position.

6. Turn the ignition switch to the START position (fully clockwise) to crank the engine. Release the key 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 cranking the engine 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 2 minutes before engaging the starter again.

7. After the engine starts, run engine at partial throttle for 30 to 60 seconds before operating the vehicle. Return to idle before engaging the travel or range select lever.

8. Move the Neutral Lock Lever to the (D) DRIVE position before you start operating.

9. Disengage the parking brake switch before you start operating.

Model 8042 Rev. 11/03

Operation

Cold Starting

The engine is equipped with a 120 volt 750 watt block heater. Block heaters are recommended when temperatures drop below 10° F (-12° C). (Temperature ranges will vary when using different oil weights. Consult the engine manufacturer’s manual for other variables.)

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.

The engine is equipped with a grid heater inside the induction manifold. If the temperature drops below 40° F (4° C) the air-intake heater system will be activated when the ignition switch is turned to the RUN position. When the system is active the air-intake heater light (see page 40) will illuminate on the front dash. DO NOT turn the ignition switch to START until the airintake heater light goes OFF.

At temperatures below -10° F (-12° C), operate the engine at moderate speeds for 5 minutes before full loads are applied.

1. Enter the cab using the hand holds and adjust the seat for comfortable operation.

2. Adjust the mirrors to obtain the best rear view from the operator’s position.

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.

3. Fasten the seat belt.

4. Make sure the parking brake switch is ENGAGED.

5. Place the travel select lever in (N) NEUTRAL and move the neutral lock lever to NEUTRAL LOCK position.

6. Turn the ignition switch to the START position to crank the starter.

IMPORTANT! DO NOT crank the starting motor continuously for more than 30 seconds. Stop cranking the starter and allow the starter to cool for 2 minutes before engaging the starter again.

7. As the engine starts, release the ignition switch to the RUN position. Depress the accelerator pedal enough to provide a smooth idle speed.

Model 8042 Rev. 11/03

Operation

8. The engine oil pressure warning indicator light should go OFF within five seconds after starting. If the light remains ON, turn the ignition switch OFF immediately and check the oil level or change to a lighter weight oil. Consult the engine manufacturer’s manual for alternative oils for cold weather operation.

Jump Starting

Jump starting at the batteries or battery replacement is required when the batteries are discharged to the point where the batteries will not crank the starter.

WARNING: NEVER jump start the vehicle directly to the

starter solenoid. Death or serious personal injury could result from the vehicle lurching forward or backward and running over the person attempting to jump start the vehicle directly to the starter.

WARNING: To avoid death or serious personal injury when

jump starting with another vehicle, be certain that the two vehicles are not touching. Never jump start a frozen battery as it will explode. Keep sparks, flames and lighted smoking materials away from the battery. Lead acid batteries generate explosive gases when charging. Wear safety glasses when working near batteries.

The booster battery must be a 12 volt type. The vehicle used for jump starting must have a negative ground electrical system. To jump start the vehicle, proceed as follows:

1. Connect the positive (+) jumper cable to the positive (+) post of the discharged battery.

2. Connect the other end of the positive (+) jumper cable to the positive (+) post of the booster battery.

3. Connect one end of the negative (-) jumper cable to the negative (-) post of the booster battery.

4. Make the final cable connection to the furthest point from the batteries.

5. Follow the steps in “Normal Starting” on page 55.

6. Remove the jumper cables in the reverse order of their connection (i.e. negative cable ground connection first, etc.).

Model 8042 Rev. 11/03

Operation

Refueling

Make sure the vehicle is level to assure an accurate fuel level reading. The fuel tank is capable of holding 37 gallons (140 liters) of diesel fuel. The usable capacity of the fuel tank is 35.6 gallons (135 liters).

Fuel Types

OH0480

Use ASTM #2 diesel fuel with a minimum Cetane rating of 40. #2 diesel fuel gives the best fuel economy and performance under most operating conditions. Fuels with Cetane ratings higher than 40 may be needed in higher altitudes or extremely low ambient temperatures to prevent misfiring and excessive smoke.

• When operating at temperatures above 32° F (0° C), use

standard #2 diesel fuel.

• When operating at temperatures below 32° F (0° C), use a blend

of #1 & #2 diesel fuels, most commonly known as “winterized” #2 diesel.

WARNING: Engine fuel is flammable and can cause a fire

or an explosion. Keep sparks and open flames away from the vehicle and DO NOT use smoking materials while refueling.

Model 8042 Rev. 11/03

Fuel Cap

Unlock the fuel cap (1) through the fuel cap access hole (2). Slowly remove the fuel cap from the fuel fill neck.

Fill fuel tank.

Operation

OH1920

Reassemble the fuel cap onto the fill neck and turn to lock in place. Line up the locking tabs to reassemble a lock if desired.

Model 8042 Rev. 11/03

Operation

Stabil-TRAK System

Understanding the Stabil-TRAK System

OS1970

The following describes the three basic modes of the patented Stabil-TRAK system. The vehicle may operate in any one of these three modes.

Free Pivot Mode

With the boom below 40° (1), the Stabil-TRAK system is in the free pivot mode (2) and the rear axle is allowed to pivot freely. The frame sway will function normally. The Stabil-TRAK light will be OFF (3).

OH0703

Model 8042 Rev. 11/03

Operation

Locked Mode

With the boom above 40° (4) and by activating one or more of the functions (as follows), the Stabil-TRAK system is in the LOCKED MODE (5). The rear axle is locked so it is rigid with the frame. The Stabil-TRAK light will be ON (6).

• Engaging the parking brake switch

• Placing the travel select lever in (N) NEUTRAL

• Depressing and holding the service brake pedal

The frame sway will function slower than normal in this mode.

OH0713

Model 8042 Rev. 11/03

Operation

Slow Pivot Mode

With the boom above 40° (1), the Stabil-TRAK System is now in the SLOW PIVOT MODE (2). In this mode the rear axle is UNLOCKED and is allowed to pivot but will respond SLOWLY light will be OFF (3).

The frame sway will function normally in this mode. To check that the Stabil-TRAK System is functioning properly, refer to the

test procedure on page 169 for the proper system function.

to changes in terrain. The Stabil-TRAK

OH0724

Model 8042 Rev. 11/03

Operation

Operating

Starting Travel

1. Enter the operator cab, fasten the seat belt, start the engine, apply the service brake pedal and disengage the parking brake switch.

2. Rotate the twist grip of the range select lever (4) to 1st gear.

3. Move the travel select lever (5) to (F) FORWARD to travel in a forward direction or to (R) REVERSE to travel backward.

4. Slowly remove your foot from the service brake pedal and press the accelerator pedal to start travel.

IMPORTANT! Check for warning lights frequently during operation. Any abnormal indication should be corrected as soon as practical.

Changing Travel Direction

1. Stop the vehicle by applying the service brakes.

2. Grasp the travel select lever, pull it toward the steering wheel, then move the lever up or down in the opposite direction; (R) REVERSE or (F) FORWARD.

Model 8042 Rev. 11/03

OH3270

OH3260

Operation

Shifting Gears

1. Rotate the twist grip of the gear select lever to the next desired gear. The transmission has four forward gears and three reverse gears.

2. Use first gear for highest torque and pulling power. Use higher gears for higher ground speed. The recommendations listed in the table that follows are guidelines only. Always use good judgement when traveling with a load.

Recommended Gear/Speed for Various Load/Travel Conditions

Load Size Surface Gear Speed

No Load Smooth 4th* 0 to 20 mph (0 to 32 km/h)

Improved 3rd 0 to 14 mph (0 to 23 km/h)

Rough 2nd 0 to 6 mph (0 to 9,7 km/h)

Load Smooth 3rd 0 to 14 mph (0 to 23 km/h)

up to 4,500 lbs Improved 2nd 0 to 6 mph (0 to 9,7 km/h)

(up to 2.041 kg)

Load Smooth 3rd 0 to 14 mph (0 to 23 km/h)

4,500 to 8,000 lbs Improved 2nd 0 to 6 mph (0 to 9,7 km/h)

(2.041 to 3.629 kg)

Rough 2nd 0 to 6 mph (0 to 9,7 km/h)

Rough 1st 0 to 3.5 mph (0 to 5,6 km/h)

*NEVER travel in 4th gear when carrying a load.

NOTE: Shifting to the next higher gear may be done while the vehicle is in motion.

IMPORTANT! When downshifting, allow the engine speed to slow down before shifting to the next lower gear.

Stopping Travel

1. Apply the service brake pedal and downshift the vehicle to a lower gear if necessary to slow the vehicle until it comes to a complete stop.

2. Move the travel select lever to (N) NEUTRAL and engage the parking brake switch. For longer stops, place the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch.

Model 8042 Rev. 11/03

Operation

Steering Modes

IMPORTANT! DO NOT change steering modes unless you are at a complete stop and all four tires are in the “straight-ahead” position.

The three steering modes are:

• Four Wheel Steering (1)

• Front Wheel Steering (2)

• Crab Steering (3)

The steering modes can be changed using a single rocker switch (4) located in the lower switch bank on the right side dash panel.

Model 8042 Rev. 11/03

OH3360

Operation

Four Wheel Steer Indexing

If the vehicle does not drive “straight,” the steering could be ”out of phase.” Perform the “Four Wheel Steer Indexing Procedure” on page 175 to synchronize the front and rear steering.

1. Four Wheel Steering

WARNING: NEVER use the Four Wheel Steering Mode

when traveling at high speed. Rapid turning in this mode can cause tipover. Use only the Front Wheel Steering Mode at higher speeds and slow the vehicle when turning.

The front wheels will steer in the direction that the steering wheel is turned; the rear wheels will steer in the opposite direction. This steering mode allows an extremely short turning radius and enables the rear wheels to follow the tracking of the front wheels which can be an advantage in mud and sand conditions.

OH1660

Model 8042 Rev. 11/03

Operation

2. Front Wheel Steering

The front wheels will steer in the direction that the steering wheel is turned. The rear wheels will remain in a fixed forward position. This steering mode should be used when loading or unloading the vehicle from a trailer and for on-highway travel at higher speeds.

OH1670

Model 8042 Rev. 11/03

Operation

3. Crab Steering

WARNING: NEVER use the Crab Steering Mode when

traveling at high speed. Rapid turning in this mode can cause tipover. Use only the Front Wheel Steering Mode at higher speeds and slow the vehicle when turning.

All wheels will steer in the same direction that the steering wheel is turned. This steering mode allows the operator to move the vehicle “sideways” toward the landing point of a load. This is especially useful on a congested worksite in order to line up at the exact spot in front of the loading location.

OH1680

Model 8042 Rev. 11/03

4. Maximum Fork Sweep

CAUTION: Allow for adequate clearance between the

attachment and other objects when turning.

The attachment extends beyond operator must be aware of the maximum sweep (2) of the attachment when turning in order to avoid hitting personnel and other objects in the area.

Operation

the end of the vehicle (1). The

OH1690

Leveling Frame

When placing a load while on a slope, use the frame sway control to keep the vehicle level. The operator should observe the frame level indicator to assure that the vehicle is level at all times.

DANGER: Use of the frame sway control with the boom

raised above horizontal can cause tipover resulting in death or serious personal injury. Always use the frame sway control to level the vehicle before cannot be leveled using the frame sway control, reposition the vehicle.

Model 8042 Rev. 11/03

raising the boom above horizontal. If the vehicle

Operation

Quick Attach

This vehicle is equipped with a quick attach system for easy attachment changing.

Attachment Removal

Be sure you are performing this procedure on level ground.

1. Place the travel select lever in (N) NEUTRAL, come to a complete stop, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch.

2. Extend the boom approximately 10 feet (3 meters) and tilt the carriage backward.

3. Exit the vehicle using the hand holds.

NOTE: If you are removing a standard carriage with forks, spread the forks apart on the carriage shaft. This will provide the carriage adequate support to stand alone.

4. Raise the quick attach pin lock lever (1) and pull out the pin (2) at the bottom of the quick attach link (3).

5. Return to the operators compartment, fasten the seat belt and lower the attachment to the ground in a level position. Tilt the attachment forward. This will rotate the quick attach link back away from the attachment.

6. Lower and then retract the boom until the attachment pivot pins have disconnected from the attachment.

Model 8042 Rev. 11/03

OS0331

Operation

Attachment Reconnect

Be sure you are performing this procedure on level ground.

1. Position the vehicle directly behind the attachment to be mounted.

2. Tilt the quick attach backward.

3. Extend the boom approximately 10 feet (3 meters) and drive the vehicle forward until the attachment pivot pins are below and between the two hooks on the attachment.

4. Raise the boom until the attachment pivot pins have seated fully in the hooks of the attachment.

5. Tilt the attachment up slightly. The quick attach link should be tight against the rear of the attachment and the holes in the link and the attachment should be aligned.

6. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and exit the vehicle using the hand holds.

7. Lift the quick attach lever (1). Insert the quick attach pin (2) completely through the attachment and the quick attach link (3). Be sure that the quick attach lock lever has lowered and seated itself into the groove in the quick attach pin.

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.

8. Return to the cab, fasten the seat belt and resume operation.

Model 8042 Rev. 11/03

Operation

Using The Capacity Chart

The individual capacity charts are located inside a booklet (1) on the right side of the front dash. Capacity charts are provided to assist the operator in determining how far in front, how high and at what angle a specific load can be safely handled with this vehicle.

8042

The vehicle is equipped with two indicators that will assist the operator in determining how to accurately use the capacity chart. These indicators are:

• Boom Extend Letters (2)

• Boom Angle Indicator (3)

OH2920

ABCABC

OH1960

Model 8042 Rev. 11/03

Operation

As the boom is extended, boom extend letters (2) will appear on the left side of the intermediate boom (4) visible to the operator. The letters are graduated in four foot increments. These letters indicate the point of boom extension and correspond to the capacity chart. For example, when the letter “A” first appears, the boom is at the point of boom extension corresponding to the arc of line “A” throughout all of the capacity charts that follow.

The boom angle indicator (3), located on the left side of the outer boom (5), indicates the angle of the boom and also corresponds with the angles indicated on the capacity chart.

To accurately use the capacity chart, the operator must first determine three important things:

1. Weight

2. Height

3. Distance tires.

of the load being lifted.

of the structure where the load is to be placed.

where the load will ultimately be placed in front of the front

WARNING: DO NOT exceed rated capacities. Any attempt

to lift or carry loads in excess of those shown on the capacity charts in the operator's compartment may cause vehicle tipover, loss of load or structural damage which could result in death or serious injury.

Model 8042 Rev. 11/03

Operation

Reading The Capacity Chart

Example (1):

1. The operator has placed the load onto the forks, fully retracted the boom, positioned the vehicle perpendicular to the structure and leveled the vehicle.

2. The operator then determines that:

• The load weight is 4,000 pounds (1.814 kg).

• The height of the structure the load is to be placed upon is 26

feet (7,9 meters) from ground level.

• The distance where the load will ultimately be placed in front of

the vehicle is 17 feet (5,2 meters) from the front of the front tires.

3. After applying the height of the structure and the distance of load placement away from the vehicle to the capacity chart, the operator knows that it will be safe to place the load if the boom extend letter “D” has appeared and the boom angle indicator reading does not go below approximately 40°. This condition is however, a maximum limit for this weight, height and distance away from the vehicle. The operator should move the vehicle closer to the structure to assure that the vehicle will not exceed the maximum limits for placing the load.

Model 8042 Rev. 11/03

Standard Carriage Capacity Chart

8042

WITH SKY TRAK MANUFACTURED STANDARD CARRIAGES ONLY

28 4812162024 0 ft

68°

Operation

0 ft

-4

60°

50°

40°

8 0

30°

20°

10°

0°

-4°

2 5

0 0

b s

4 0

0 0

b s

0 0

b s

24

ASME B56.6 - 2002 PART lll

4110438

Model 8042 Rev. 11/03

OH2932

Operation

Side Tilt Carriage Capacity Chart

8042

WITH SKY TRAK MANUFACTURED SIDE TILT CARRIAGES ONLY

SAFETY INSTRUCTIONS

0 ft

-4

60°

50°

812162024 0 ft

68°

Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers.

40°

30°

4 0

20°

10°

0°

2 5

0 0

b s

24

-4° 27

9.5

ASME B56.6 - 2002 PART lll

4110439

OH2942

Model 8042 Rev. 11/03

Swing Carriage Capacity Chart

8042

WITH SKY TRAK MANUFACTURED SWING CARRIAGES ONLY

28 4812162024 0 ft

68°

50°

60°

40°

30°

20°

Operation

SAFETY INSTRUCTIONS

Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers.

10°

0°

0 ft

-4°

-4

Model 8042 Rev. 11/03

27.5

22.5

18.5

9.5

24

ASME B56.6 - 2002 PART lll

4000lbs 4000lbs

3000lbs2000lbs1300lbs

4000lbs

6000lbs 8000lbs

4110440

OH2952

Operation

12 Foot Truss Boom Capacity Chart

8042

WITH SKY TRAK MANUFACTURED 12' TRUSS BOOMS ONLY

28 4812162024 0 ft

20°

10°

0°

-4°

30°

40°

323640

60°

50°

2 0 0

5 0 0

l b s

0 ft

-4

12'

SWINGING LOADS can cause MACHINE TIPOVER which can result in death or serious injury.

ALWAYS  travel slowly  rig properly  use two tethers

3035.5

ASME B56.6 - 2002 PART lll

4110441

OH2962

Model 8042 Rev. 11/03

3 Foot Truss Boom w/Winch Capacity Chart

8042

WITH SKY TRAK APPROVED TRUSS BOOM WINCH ONLY

50°

812162024 0 ft

68°

60°

SAFETY INSTRUCTIONS

Use only with vehicles equipped with auxiliary hydraulics. Always connect couplers.

Operation

20°

40°

30°

10°

0°

0 ft

-4°

-4

Model 8042 Rev. 11/03

SWINGING LOADS can

cause MACHINE TIPOVER which can result in death

or serious injury.

ALWAYS  travel slowly  rig properly  use two tethers

1621

ASME B56.6 - 2002 PART lll

4110376

OH3580

Operation

This Page Intentionally Left Blank

Model 8042 Rev. 11/03

Operation

Fork Ratings

All approved forks for this vehicle are marked with a maximum load capacity rating. This rating is stamped on the left edge of the fork (1) 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). This rating specifies the maximum load capacity that the individual fork can safely carry at a maximum load center (4) of 24" (610 mm).

Since forks are always used in multiples, the total rating of any combination of forks will be the sum of their rated capacity. Other than block forks, all forks should be used in matched pairs. Block forks should be used in matched sets.

XXXX - 24

OU0131

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 not be exceeded.

The maximum load capacity for this vehicle is 8,000 pounds (3.629 Kg). The matched pair or set of forks used on this vehicle should have total load ratings which equal or exceed 8,000 pounds (3.629 Kg). When the load rating of the vehicle differs from the load capacity of the forks, the lower value becomes the overall load capacity.

Model 8042 Rev. 11/03

the capacity of the vehicle, the vehicle capacity should

Operation

How To Pick, Carry & Place A Load

To pick a load, tilt the carriage forward so the forks hang freely on the fork shaft. Move the forks inward or outward on the fork shaft so that they are aligned with the openings in the pallet. Tilt the carriage back and extend the boom slowly so the forks slide into the openings in the pallet. Raise the boom so that the load is lifted.

To carry a load, position the boom so that the load is as low as possible and the travel area is visible to the operator.

Use the capacity chart to determine safe boom extension range for the applicable load. To place a load, align the forks at the level the load is to be placed and then extend the boom slowly until the load is just above the area where it is to be placed. Lower the boom until the pallet rests in position and the forks are free to retract. Retract the forks slowly

from under the load.

Elevating Personnel

This vehicle is designed to lift and transport materials and should not be used to elevate personnel except as explained in this section. Only equipment designed and approved for elevating personnel should be used.

If the vehicle must be used to elevate personnel, use only a compliant work platform. Refer to “Defining Platforms For Elevating Personnel” on page 82 for requirements. When using a work platform, the following precautions must be taken:

WARNING: Use only a compliant work platform to lift or

lower personnel. Never drive the vehicle with the work platform in a raised position or with personnel on board, even for a short distance.

Defining Platforms For Elevating Personnel

The requirements for platforms shall include the following:

1. The platform floor must have a slip resistant surface not more than 8" (200 mm) above the normal load supporting surface of the forks.

2. The platform floor dimensions shall not exceed: a. Two times the load center distance as listed on the load chart

that is attached to the vehicle. This floor dimension is measured parallel to the longitudinal center plane of the vehicle.

Model 8042 Rev. 11/03

Operation

b. Width of the platform shall not be wider than the width of the

vehicle, measured across the load bearing tires plus 10" (250 mm) on each side.

c. Minimum space requirements for each person on the platform

shall not be less than 18" (450 mm) in either direction.

3. The platform shall have a 4" (100 mm) minimum high toe plate around the perimeter of the platform. The toe plate may be omitted at the access opening.

4. Protection must be provided for the personnel on the work platform from any pinch points or moving parts while in their normal working position on the platform.

5. Information prominently indicated on the work platform shall include:

a. Maximum work load including personnel and equipment.

b. Weight of the empty platform.

6. Provide a means to securely mount and attach the platform so it can:

a. Only be centered laterally on the vehicle and retained against

the vertical face of the forks, carriage or the lifting mechanism.

b. Prevent the platform from inadvertent pivoting.

7. The platform must have a restraining means such as a guardrail or a means of securing personnel such as a body belt or lanyard for each occupant of the platform.

8. The guardrail or similar structure shall have a nominal height to the platform floor of 42" (1066 mm) around the perimeter of the platform and include a midrail. The guardrail openings may be used to provide alternate access openings provided the opening can be easily made by hinging or removing sections, but must be easily put back into original position when alternate openings are no longer required.

9. The guardrail shall be capable of withstanding a concentrated horizontal force of 200 lb (890 N) applied at the point of least resistance without permanent deformation.

Model 8042 Rev. 11/03

Operation

10. A body belt and lanyard is to have an attaching point for freedom of movement, and its length is to limit free fall to 5 feet (1500 mm) measured from the point of attachment to the operator. The complete system shall be capable of withstanding three consecutive drop tests to simulate a 250 lb (113 kg) person falling 6 feet (1800 mm) without allowing the test weight to fall free to the ground. A deceleration device may be included.

11. Lanyards, when provided, shall be arranged so as not to cause a tripping hazard.

12. Body belts, when provided, should have a width of at least 1.75 in. (44 mm).

13. Structural safety factor - all load supporting structural elements of the work platform shall have a structural safety factor of not less than 2 to 1 based on the minimum yield strength of materials used.

Capacity Limitations

The combined mass (weight in pounds) of the platform, load and personnel shall not exceed one-third position indicated on the capacity chart. Refer to “Using The Capacity Chart” on page 72.

Preparation and Set-up

(33%) of the capacity of the related load center

WARNING: Never allow anyone to alter or modify any part

of the work platform. Any modification to the platform which could result in serious personal injury to anyone on the platform.

1. DO NOT alter or modify the work platform in any manner.

2. Make sure that the work platform is securely attached to the quick attach or forks. Follow the platform manufacturer’s instructions.

3. Make sure the platform, carriage and forks are secured to prevent them from pivoting from side to side.

4. On side tilt or swing carriages, the carriage must be centered and/ or leveled horizontally and vertically. The hydraulic system quick disconnects must also be disconnected and plugged and the carriage securely fastened to prevent any tilting or side to side swinging motion.

5. Ensure the vehicle has a firm footing and is level.

Model 8042 Rev. 11/03

Operation

6. Be sure the vehicle is in a level position (side to side) before any operation is begun. Use the frame sway to level the vehicle. If the vehicle cannot be leveled, reposition the vehicle.

7. Place the travel select lever in the (N) NEUTRAL position and move the neutral lock lever to the NEUTRAL LOCK position.

8. Engage the parking brake switch. Blocking the wheels is also recommended.

9. Level the platform in both the side-to-side and front-to-back directions before use.

10. Before lifting or lowering personnel, be sure the vehicle lifting mechanism operates smoothly through the entire lifting and lowering of the platform and maintains its self leveling function. The vehicle must operate smoothly both empty and loaded.

11. Be sure any lift limiting devices and latches are functioning properly.

12. Any body belt, lanyard or deceleration devices which have sustained any deformation or damage must be replaced before using the work platform again.

13. Before elevating personnel, the area around and under the work platform should be marked to warn anyone on the ground that overhead work is being done.

14. Protection must be provided for the personnel on the work platform from any pinch points or moving parts while in their normal working position on the platform.

15. Provide any overhead protection device as required by worksite conditions or if requested by the user of the platform.

Model 8042 Rev. 11/03

Operation

Elevating Personnel

WARNING: Never operate the Attachment Tilt function to

tilt the platform forward or rearward when elevating with personnel aboard. Death or serious personal injury could result.

DANGER: Never operate this or any equipment in an area in

which overhead or underground cables or power sources exist without first requesting that the appropriate power company or utility company de-energize the lines or take other suitable precautions.

1. Make sure there are no overhead obstructions or electrical wires above the platform before lifting.

2. A trained operator must operate the controls from the operators compartment and must remain with the vehicle at all times. Using extreme caution, lift and lower personnel smoothly and only at their request. The operator should move the platform up and down only in response to instruction from personnel on the platform. If the operator must move the platform, the operator must alert the personnel aboard the platform before moving.

3. Personnel aboard the work platform must maintain a firm footing at all times.

4. Be certain the personnel and related equipment on the platform do not exceed the available space of the platform.

5. The platform shall be lowered to the ground level for personnel to enter or exit the platform through the appropriate platform access opening. Personnel must not climb on any part of the vehicle or over the platform guardrails in an attempt to enter or exit the platform.

6. Always position the platform in the travel position (approximately one foot above ground level) before moving the vehicle.

IMPORTANT! Make sure that required restraining equipment such as railings, chains, cable, body belts with lanyards, etc. are in place and properly used. Never use railings, planks, ladders, etc. on the platform for the purpose of achieving additional reach or height.

Model 8042 Rev. 11/03

Operation

Using Other Attachments

Numerous attachments, marketed by JLG are available for this vehicle. The capacity charts attached to this vehicles dash are to be used with SKY TRAK approved attachments only. Hydraulically powered attachments must only be used on vehicles equipped with auxiliary hydraulics.

IMPORTANT! This vehicle is intended for the function of lifting only. This vehicle is not designed to PULL, TOW or DRAG other objects.

JLG makes no representations or warranties, expressed or implied, as to the design, manufacture or fitness for use with this vehicle of any third party source attachment. This vehicle is not intended to be used and should not be used with an attachment that would alter the center of gravity or stability of this vehicle. JLG assumes no liability for any third party attachment that would alter the center of gravity or stability.

IMPORTANT! DO NOT use unapproved attachments.

Following is a list of some of the attachments available through JLG for this vehicle model:

• 48" Standard Carriage

• 60" Standard Carriage

• 72" Standard Carriage

• 1-1/4 Cubic Yard Bucket

The standard capacity chart on page 75 is applicable for the above listed attachments.

The attachments listed below are supplied with their own individual capacity chart:

• 48, 60 & 72" Side Tilt Carriage (page 76).

• 52 & 72" Swing Carriage (page 77).

• 12 Foot Truss Boom (page 78).

• 3 Foot Truss Boom w/Winch (page 79)

Hydraulically actuated attachments also have a maximum hydraulic pressure rating. Ensure that the maximum rated hydraulic pressure of the attachment is equal to or slightly greater than 3,000 psi (206,8 bar), which is the maximum pressure of the vehicle’s auxiliary hydraulics at the quick disconnect couplers.

Model 8042 Rev. 11/03

Operation

Shut-Off

1. Bring the vehicle to a complete stop using the service brakes.

2. Park the vehicle on level ground.

WARNING: To prevent death or serious personal injury, be

certain to lower the boom, engage the parking brake switch, and shut off the engine prior to exiting the vehicle.

3. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch.

4. Lower the boom and ground the carriage.

5. Turn the ignition key to the OFF position and remove the key.

Model 8042 Rev. 11/03

Emergency Operations

Towing A Disabled Vehicle

Towing a disabled vehicle should only be attempted 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 Sky Trak Distributor or the JLG Service Department at (877) 554-5438 or (717) 485-6657 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.

WARNING: BLOCK ALL FOUR WHEELS. Failure to do so

could result in death or serious injury from vehicle roll-away.

2. Block all four wheels to help prevent the vehicle from moving after

the parking brake is disabled.

3. Remove the six hex nuts (1) securing the transmission covers (2) to the frame. Remove the covers.

Model 8042 Rev. 11/03

OH2372

Emergency Operations

4. Position the towing vehicle in place. Attach any chains needed to secure the disabled vehicle.

5. Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port (1) on the secondary function manifold (2) mounted on the inside wall of the frame (3) on the left side next to the transmission.

6. Turn the key switch to the ON position (with the engine not running), release the park brake (park brake switch OFF), and have an operator seated in the seat.

Front Of

Vehicle

OH1840

7. Pressurize the park brake with the pressurizing unit. Close the pump needle valve on the pressurizing unit.

CAUTION: DO NOT exceed 575 psi (40 bar) when pressur-

izing the park brake. Applying too much pressure may damage the brake seals.

8. Clear the area of all unnecessary personnel.

9. Carefully remove the wheel blocks from each of the four tires. Tow the vehicle to a secure location.

IMPORTANT! Without engine power, service braking power is reduced. Only the rear service brakes will function when the brake pedal is depressed. Steering is not possible and the vehicle will only travel in the direction that the wheels were last truned. Tow or push the vehicle at a

very slow speed!

Model 8042 Rev. 11/03

Emergency Operations

Emergency Boom Lowering

This section discusses emergency boom lowering procedures:

Part I In case of loss of engine power or hydraulic pump failure. Part II In case of hydraulic line failure.

Part I Loss of Engine Power or Hydraulic Pump Failure

IMPORTANT! In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis. Contact your local Sky Trak Distributor or the JLG Service Department at (877) 554-5438 or (717) 485-6657 for specific instructions for your particular situation.

In any event, the vehicle should be secured until the situation has been properly evaluated. Secure the vehicle by following the procedures below:

1. Clear the area around the vehicle of all personnel.

2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch.

3. Block all four wheels.

4. Section off a large area under the boom with string or tape to restrict any personnel from entering this potentially dangerous area.

WARNING: DO NOT get under a raised boom unless the

boom is blocked up. Always block the boom before vicing that requires the boom to be up.

5. Temporarily block up or support the outer boom so it cannot be lowered.

6. If the load is in a position where it can be removed safely, completely remove the load from the carriage and/or attachment, otherwise leave the load in place.

7. Place an accident prevention tag on both the ignition switch and steering wheel. Refer to “Accident Prevention Tags” on page 5. Actual accident prevention tags can be found as the last page of this manual. If you do not have a safety tag, tape over the ignition switch.

Model 8042 Rev. 11/03

doing any ser-

Emergency Operations

Part ll - Hydraulic Line Failure

In case of hydraulic line failure, there are step-by-step procedures available to assist you in safely retracting and then lowering the boom. Read Part II from start to finish before performing any of these procedures so you fully understand the process and the danger involved. If you are unsure about any part of these procedures contact your local Sky Trak Distributor or the JLG Service Department.

Every attempt should be made to repair the hydraulic line failure and to retract and then lower the boom in its normal fashion. We realize this is not always possible. Step-by-step procedures are also available when the boom must be retracted and lowered immediately and replacement parts are not available. Only resort to Steps 3 & 4 when absolutely necessary.

IMPORTANT! Be aware that the boom must first be retracted and then lowered to avoid vehicle tipover.

OH2211

Model 8042 Rev. 11/03

Emergency Operations

In any case of hydraulic line failure, it is critical to correctly identify which hydraulic line has failed. Identify the hydraulic line that has failed and use the table that follows to determine which Step to follow to retract and lower the boom. The hydraulic lines are:

• Boom Lift Line (1)

• Boom Lower Line (2)

• Boom Extend Line (3)

• Boom Retract Line (4)

able

HYDRAULIC

LINE

THAT

FAIL ED

BOOM LIFT LINES

(LIFT CYLINDERS TO

CONTROL VALVE)

BOOM LOWER LINES

(LIFT CYLINDERS TO

CONTROL VALVE)

NORMAL STEPS

THIS STEP

IF PARTS

ARE

AVAILABLE

STEP 1 STEP 2

STEP 1

THIS STEP

IF PARTS ARE NOT

AVAILABLE

EMERGENCY STEPS

OP0330

FOLLOW THIS STEP

AS A LAST RESORT

STEP 3

BOOM

EXTEND

LINE

BOOM

RETRACT

LINE

Model 8042 Rev. 11/03

STEP 1 STEP 2

STEP 1

STEP 4

Emergency Operations

STEP 1

1. Clear the area of any unnecessary personnel.

2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch.

3. Block all four wheels.

WARNING: DO NOT get under a raised boom unless the

boom is blocked up. Always block the boom before vicing that requires the boom to be up.

4. If the load is in a position where it can be removed safely, completely remove the load from the carriage and/or attachment; otherwise, leave the load in place.

5. Temporarily block up or support the outer boom.

doing any ser-

WARNING: Wear protective clothing and proper eye pro-

tection when working with or around hydraulic oil. Wait for hydraulic oil to cool before attempting to repair the failure. Hot hydraulic oil can cause severe burns and other serious injury.

6. Replace the failed hydraulic line with a new part. The hydraulic lines are:

• Boom Lift Line (1)

• Boom Lower Line (2)

• Boom Extend Line (3)

• Boom Retract Line (4)

7. Check the hydraulic oil level, add oil if needed.

8. Remove the blocking or support from the outer boom.

9. Return to the cab, fasten your seat belt and start the engine.

10. Tilt the carriage and/or attachment upward if necessary for clearance before retracting the boom.

11. Slowly retract the boom.

12. Slowly lower the boom and ground the carriage and/or attachment.

Model 8042 Rev. 11/03

Emergency Operations

13. Shut off the engine.

14. Completely remove the load from the carriage and/or attachment if

you haven’t already done so.

15. Return to the cab, fasten your seat belt and start the engine.

16. Cycle the lift and extend cylinders several times to bleed air from

the system. Check for leaks.

17. Recheck the hydraulic oil level. Add oil if necessary.

Model 8042 Rev. 11/03

OH2211

Emergency Operations

STEP 2

USE IN CASE OF: BOOM LIFT LINE FAILURE (Lift Cylinders to Control Valve) BOOM EXTEND LINE FAILURE

1. Clear the area of any unnecessary personnel.

2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch.

3. Block all four wheels.

WARNING: Wear protective clothing and proper eye pro-

tection when working with or around hydraulic oil. Wait for hydraulic oil to cool before attempting to repair the failure. Hot hydraulic oil can cause severe burns and other serious injury.

4. Place a container under the failed hose to catch any hydraulic oil that may escape during this procedure.

5. Return to the cab, fasten your seat belt and start the engine.

6. Slowly retract the boom.

7. Slowly lower the boom and ground the carriage and/or attachment.

8. Shut off the engine.

9. Completely remove the load from the carriage and/or attachment.

10. Place an accident prevention tag on both the ignition switch and steering wheel. Refer to “Accident Prevention Tags” on page 5. Actual accident prevention tags can be found as the last page of this manual. If you do not have a safety tag, tape over the ignition switch.

11. Have the vehicle serviced immediately. lic lines with new parts. The hydraulic lines are:

• Boom Lift Line (1)

• Boom Lower Line (2)

• Boom Extend Line (3)

• Boom Retract Line (4)

Replace any failed hydrau-

Model 8042 Rev. 11/03

Emergency Operations

12. Return to the cab, fasten your seat belt and start the engine.

13. Cycle the lift cylinder several times to bleed air from the system.

Check for leaks.

14. Recheck the hydraulic oil level. Add oil if necessary.

15. Transfer any waste oil to a container with a cover and label as used

oil. Dispose of properly.

Model 8042 Rev. 11/03

OH2211

Emergency Operations

STEP 3

BOOM LOWER LINE FAILURE (Lift Cylinders to Control Valve)

1. Clear the area of any unnecessary personnel.

2. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position and engage the parking brake switch.

3. Block all four wheels.

WARNING: DO NOT get under a raised boom unless the

boom is blocked up. Always block the boom before vicing that requires the boom to be up.

4. Temporarily block up or support the outer boom.

5. If the load is in a position where it can be removed safely, completely remove the load from the carriage and/or attachment; otherwise, leave the load in place.

6. Place a 10 gallon (40 liter) container under the vehicle to catch any hydraulic oil that will escape during this procedure.

doing any ser-

WARNING: Wear protective clothing and proper eye pro-

tection when working with or around hydraulic oil. Wait for hydraulic oil to cool before attempting to repair the failure. Hot hydraulic oil can cause severe burns and other serious injury.

NOTE: If a replacement hose is not available, the adjacent boom lift line (1) can be used to replace the failed boom lower line (2).

7. Remove the individual failed boom lower line from the circuit.

8. Remove and temporarily reposition the adjacent boom lift line (1) in place of the failed boom lower line (2).

IMPORTANT! Once either boom lift line is removed and the boom is retracted during the remaining steps, hydraulic oil will drain out of the base end of the boom cylinder. The escaping oil should be deflected by some means (the failed hose could be used) directing the oil into the drain container.

Model 8042 Rev. 11/03

SkyTrak 8042 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

The Manual

Replacement Parts

Reports

Safety Practices

Disclaimer

Hazard Classification System

Signal Word

Accident Prevention Tags

New or Additional Operators

Instructional Symbols

Hazard Symbols

Avoidance Symbols

Avoidance Symbols (cont’d)

Personal Considerations

1. Seat Belt

2. Clothing and Safety Gear

3. Dismounting

4. Chemical Hazards

A. Exhaust Fumes

B. Explosive Fuel

C. Ether or High Energy Starting Aids

D. Hydraulic Fluid

E. Batteries

Battery Electrolyte First Aid:

5. Moving Parts Hazard

6. Lowering Boom or Falling Load Hazard

Operational Considerations

1. Preparation and Prevention

2. Clearances

3. Visual Obstruction

4. Underground Hazards

5. Electrocution Hazards

6. Elevating Personnel

7. Tip Over Hazard

8. Emergency Exit Rear Window

9. Tire Pressure

10.Do Not Jump

11.Slopes

12.Falling Load Hazard

13.Ventilation

Equipment Considerations

Operation

Operator Controls

Accelerator Pedal

Service Brake Pedal

Steering Wheel

Horn Button

Ignition Switch

Steering Select Switch

Park Brake Switch

Neutral Lock Lever

Travel Select Lever

Gear Select Lever

Recommended Gear/Speed for Various Load/Travel Conditions

Load Size Surface Gear Speed

No Load Smooth 4th* 0 to 20 mph (0 to 32 km/h)

Improved 3rd 0 to 14 mph (0 to 23 km/h)

Rough 2nd 0 to 6 mph (0 to 9,7 km/h)

Load Smooth 3rd 0 to 14 mph (0 to 23 km/h)

up to 4,500 lbs Improved 2nd 0 to 6 mph (0 to 9,7 km/h)

(up to 2.041 kg)

Load Smooth 3rd 0 to 14 mph (0 to 23 km/h)

4,500 to 8,000 lbs Improved 2nd 0 to 6 mph (0 to 9,7 km/h)

(2.041 to 3.629 kg)

Rough 2nd 0 to 6 mph (0 to 9,7 km/h)

Rough 1st 0 to 3.5 mph (0 to 5,6 km/h)

Boom Control Lever

Attachment Tilt and Frame Sway Control Lever

Seat Belt

Operator’s Seat Adjustment

A. Fore and Aft Adjustment

B. Suspension Adjustment

C. Backrest Angle Adjustment

Instruments and Indicators

Hourmeter