Skytrak MMV Owner's/operator's Manual

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8990504

OWNERS/OPERATORS

MANUAL

Model MMV

(S/N MV201 & After)

(Tier 2)

OM0652

TM 10794B-12/1

Printed in U.S

.A. 10/11

PCN 500 107943 00

WARNING: Improper operation of this vehicle can

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

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 vehicl e.

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.

Revision Log

December 17, 2004 - B - Replaced all branding with JLG. October 12, 2011 - C - Revised pages 22, 27, 66, 67, 70, 157, 170, 171, 182 thru

185, 193, 201, 218, 219, 221, 222 & 246.

REVISION LOG

8990504

Revision Log

8990504

Table of Contents

Revision Log Introduction

The Manual....................................2

Replacement Parts........................2

Reports..........................................2

Disclaimer......................................3

Safety Practices

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

Front Dash Panel.........................54

Instruments and Indicators..........61

Pre-Operation Inspection.............66

Normal Starting............................67

Cold Starting................................68

Slave Starting..............................70

Refueling .....................................71

Operating.....................................73

Carriages.....................................84

Using the Capacity Chart.............92

Load Capacity To Travel

Speed Tables ...........................94

Fork Rating................................104

How To Pick, Carry & Place

A Load.................... ... .............105

Elevating Personnel...................107

Shut-Off.....................................113

Emergency Operations

Towing a Disabled Vehicle........114

Emergency Boom Lowering ......123

General Maintenance

Introduction................................137

Maintenance Schedule and

Checklist.................................138

1. Lubrication Points ................141

2. Air Cleaner...........................143

3.Closed Cab Air Filters...........147

4.Engine Cooling System ........148

5.Engine Oil and Filter .............152

6.Engine Fuel System..............157

7.Engine Fan Belt....................162

8.Air Conditioner

Compressor Belt ...............163

9.Hydraulic Oil and Filter .........164

10.Transmission Oil

and Filter...........................169

11.Axle Oil ...............................172

12.Brake Disk Inspection.........175

13.Wheel End Oil.....................179

14.Transfer Case Oil................182

15.Wheels and Tires................186

16.Emergency Tire

Inflation System.................188

17.Batteries..............................192

18.Fuse & Relay

Replacement.....................194

19.Boom Chains and

Wear Pads ........................203

Storage and Transport ..............218

Short Term Storage...................218

Long Term Storage...................220

Counterweight Removal

and Reassembly.....................223

Transport...................................226

Test Procedures

Stabil-TRAK™ System Test ......236

Parking Brake/Transmission

De-Clutch

Test Procedures.....................241

Four Wheel Steer Indexing

Procedure...............................244

Specifications

Fluid & Lubrication Capacities...245

Tires .......................................... 247

Weights .....................................248

Vehicle Dimensions...................249

Electrical System.......................250

Engine.......................................252

Index.............................................255

Accident Prevention Tags

Replacement Manuals...................1

This document has been prepared by JLG Industries Inc. for the USMC, 2004.

Approved for public release; distribution is unlimited.

Introduction

OM1370

Introduction

The Manual

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

IMPORTANT! Before and carefully so you will understand the instructions and the operation of the controls and equipment. You must comply with all Danger, Warning, and Caution notices; they are for your benefit.

All references to the right side, left side, front, or rear are given from the operator's seat looking forward.

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 re pla ce m en t 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 adve rsely affect the perfo rmance, durability or safety of this vehicle.

Reports

IMPORTANT! A Warranty Registration form must be filled out by the JLG Authorized Service Center (ASC), 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 Authorized Service Center (ASC) has returned th e business reply card of this form to JLG.

Model MMV Rev. 10/11

Safety Practices

OP0330

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 d iscretion 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 operatin g 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.

Safety Practices

Hazard Classification System

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 MMV Rev. 10/11

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 e xistence 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” indica tes 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 MMV Rev. 10/11

Safety Practices

DANGER

OM1750

Accident Prevention Tags

Before beginning any maintenance or service, place an Accident Prevention Tag (1) on both the ignition switch (2) and t he 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.

New or Additional Operators

At the time of original purchase, the purchaser of this vehicle was instruct ed 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 re gu la tio ns referenced on page 3, and reads and understands this Operators Manual before

operating the vehicle.

In addition, make sure that the new operat or 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 MMV Rev. 10/11

Safety Practices

OP0330

OH2100

OH2090

Safety Alert Symbol

Read Operator’s Manual

Fasten Seat Belt

Instructional Symbols

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

Model MMV Rev. 10/11

Hazard Symbols

OH2110

Lead Acid Batteries

Generate Explosive Gases

OH2120

OH2300

OH2161

OH2130

OH2140

OH2150

Rotating Fan Blades

Can Cut

Rotating Belts Can Cut

Or Entangle

Vehicle Tipover Can

Crush

Vehicle Roll Away Can Cause

Death Or Serious Injury

Electrocution Can

Cause Death Or

Serious Injury

FALLING OFF ATTACHMENT

Can Result In Death Or Serious

Injury

OH3160

OU1450

ENGINE EXPLOSION

Can Result In Death

Or Serious Injury

AVOID CRUSHING, Falling Off

Vehicle Can Cause Death Or

Serious Injury

Safety Practices

Model MMV Rev. 10/11

Safety Practices

OH2320

Keep Lit Cigarettes

Away

OH2310

OH2280

OH2330

OH2270

OH2290

Keep Away From

Rotating Fan Blades

Do Not Raise Boom

While On A Slope

Keep Flames and

Ignition Sources Away

Do Not Travel With

Boom Raised

Maintain Proper Air

Pressure In Tire

OU1460

DO NOT Use Ether Or

Other High Energy

Starting Aids.

Engine Equipped With

Grid Heating System.

Avoidance Symbols

Model MMV Rev. 10/11

Safety Practices

OH2260

Engage Parking Brake

OH2240

OH2220

OH2250

OH2230

OH2170

Do Not Travel With

Personnel In Work

Platform

DO NOT JUMP

Keep Clear Of Power

Lines

Carry No Riders

Use Only Compliant

Work Platforms To

Raise Or Lower

Personnel

• Brace Yourself and Stay With Vehicle

• Keep Seat Belt Fastened

• Hold On Firmly

• Lean Away From The Point Of Impact

Avoidance Symbols (cont’d)

Model MMV Rev. 10/11

Safety Practices

ALWAYS

engage parking brake

before dismounting

WARNING

VEHICLE

ROL LAWAY

can cause

death or

serious

injury

OU0340

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 hazard ous 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.

Model MMV Rev. 10/11

Safety Practices

4110460

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.

OU1470

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 sys-

tem 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.

Model MMV Rev. 10/11

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. Pressure can typically be relieved by slowly and cautiously

loosening one end of a hose at the swivel

connection. If anyone is injured by or if any hydraulic fluid is injected into the

skin, obtain medical attention immediately or gangrene may result.

Safety Practices

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!

E. Batteries

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

When slave starting the vehicle, carefully follow instruction s f ound under “Slave Starting” on page 70.

Keep sparks, flames and lit smoking materials away from the batteries 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.

Model MMV Rev. 10/11

Safety Practices

MOVING PARTS can cut.

Keep clear of fan and belts while engine is running.

MOVING PARTS can entangle.

OT0810

5. Moving Parts Hazard

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

result. Turn of f engine and wait until fan and belts stop moving before

servicing.

6. Lowering Boom or Falling Load Hazard

DO NOT get under a raised boom unless it is blocked up sa fely. 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 MMV Rev. 10/11

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 and the Neutral Lock Lever is in the (N) NEUTRAL LOCK position with the parking brake switch engaged before starting the engine.

Holes, obstructions, debris and other worksite hazard s 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, machiner y 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 MMV Rev. 10/11

Safety Practices

OS0063

4. Underground Hazards

Know the location of all underground hazards before operating this vehicle in a new area or worksite. Electrical cables, ga s an d wa te r 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 powe r lines,

overhead or underground cables, or other power sour ces may exist without first requesting that the appropriate power or utility company deenergize the lines, or take other suitable precauti ons.

Model MMV Rev. 10/11

Safety Practices

WARNING

Allow no riders

AVOI D

CRUSHING,

falling off vehicle can cause death

or serious

injury

FALLING OFF ATTACHMENT,

can result in death or

serious injury.

DO NOT TRAVEL with personnel in a work platform.

4110389

Lift or lower personnel only in a compliant work platform.

WARNING

OU0620

OH3180

6. Elevating Personnel

Use only a compliant work platform meeting the ASME B5 6.6 standards for lifting and lowering per sonnel. NEVER transpo rt 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 Personne l” on page 107..

Model MMV Rev. 10/11

Safety Practices

DANGER

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

VEHICLE TIPOVER can result in death or serious injury.

DO NOT travel with the boom raised.

MAINTAIN proper tire pressure at all times.

OS0086

OU09201

7. Tip Over Hazard

Traveling with the boom raised is dangerous and can cause tipover.

Keep the boom as low as possible. Travel with ex treme 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.

If the vehicle cannot be leveled using the frame sway control, repositio n

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

8. Emergency Exit Rear Window

and at

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 MMV Rev. 10/11

Safety Practices

DANGER

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

VEHICLE TIPOVER can result in death or serious injury.

DO NOT travel with the boom raised.

MAINTAIN proper tire pressure at all times.

OS0085

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

if vehicle tips.

Jumping can

result in death

or serious

injury.

DANGER

AVOID CRUSHING

OH3190

9. Tire Pressure

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

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 MMV Rev. 10/11

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 he avy 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 Rating” on page 104.

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 exhau st 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 MMV Rev. 10/11

Safety Practices

4110468

CAUTION

ENGINE OVERHEATING can occur.

Consult Operator Manual for coolant filling procedure.

OM2290

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 JLG Authorized Service Center (ASC) 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 241. 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 and/or decal plates. Replace decals

or decal plates if missing, damaged or illegible. The following page s show the proper location of the decals and/or decal plates.

Engine cooling system MUST be properly filled and all trapped air bled from the cooling system. Refer to “Drain and Flush Radiator” on page 149 for filling and bleeding procedures.

Model MMV Rev. 10/11

Safety Practices

WARNING

Allow no riders

AVOID

CRUSHING,

falling off

vehicle can

cause death

or serious

injury

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

if vehicle tips. Jumping can

result in death

or serious

injury.

DANGER

AVOID CRUSHING

SAFETY

INSTRUCTIONS

4110361

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.

0000000

RPM X 100

1/2

104

176

248

120

°C

°F

r/min

Item Part Number Quantity Decal Description

4110358 1 No Riders Warning 2 4110358 1 Vehicle Rollaway Warning 3 4108991 1 Electrocution Danger

4 6623762 1

Load Chart Booklet - 87 psi (600 kPa) Full Tire Pressure

5 6623944 1

Load Chart Booklet - 60 psi (414 kPa) Reduced Tire Pressure

6 6623997 1

Load Chart Booklet - 45 psi (310 kPa)

Reduced Tire Pressure 7 4110137 1 Tipover Danger 8 4110358 1 Do Not Jump Danger 9 41 10361 1 Safety Instructions

OM1760

4 5 6

Model MMV Rev. 10/11

Safety Practices

MOVING PARTS can cut.

Keep clear of fan and belts while engine is running.

MOVING PARTS can entangle.

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.

3Y949-4110463

3Y949-4110304

WARNING

DO NOT TRAVEL with personnel in a work platform.

FALLING OFF ATTACHMENT,

can result in death or

serious injury.

Lift or lower personnel only in a compliant work platform.

4110468

CAUTION

ENGINE OVERHEATING can occur.

Consult Operator Manual for coolant filling procedure.

1YHH8-1706549

CAGE CODE

S/N

NSN

CONTRACT NO.

NOMENCLATURE

TRUCK, LIFT FORK, VARIABLE REACH ROUGH TERRAIN MODEL: SKYTRAK MMV GVW: 26,900 LBS CAPACITY: 11000 LB SHIPPING WEIGHT: 30,500 LBS NSN: DES. ACT/MFR: 1YHH8 HEIGHT 93.6 IN. WARRANTY: MO. WIDTH 100.2 IN. DATE OF MFR.: CUBE 1796.5 CU. FT. DATE SHIPPED: REG. NO. DATE INSPECTED & STAMP:

CONTRACT

SERIAL

NO.

1YHH8-1001092290

1001121649_A

SLAVE 24 VOLTS DC

SHIPPING DATA FOR

SKYTRAK MMV

TRUCK, LIFT FORK, VARIABLE REACH

ROUGH TERRAIN, 11,000 POUND CAPACITY

1YHH8-4110306

1YHH8-1706549

CAGE CODE

S/N

NSN

CONTRACT NO.

NOMENCLATURE

Model

1YHH8-6623990

Serial Number

Year of Manufacture

Max Weight Without Attachments Max Capacity

Sky Trak

OM20502

1YHH8-1706549

CAGE CODE

S/N

NSN

CONTRACT NO.

NOMENCLATURE

Item Part Number Quantity Decal Description

4110184 4 Moving Parts Warning 2 4110303 2 Explosive Gases Warning 3 4110304 1 Carrying Personnel Warning 4 4110305 1 Boom Angle Indicator 5 4110463 2 Ether Start Warning 6 4110468 1 Coolant Filling Caution 7 1001092290 1 Machine Identification Plate 8 1706549 6 Universal ID Plate 9 6623390 1 MMV Serial Number Plate

10 4110306 1 Shipping Data Plate 11 1001121649 1 Slave Decal, 24V DC 12 3576086 1 Engine Identification Plate

7 8

1288

Model MMV Rev. 10/11

Operation

OM1770

Operation

Operator Controls

Accelerator Pedal

Pressing down the accelerator pedal (7) 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 in the RUN position, depress and release the pedal 3 times to activate the system.

Service Brake Pedal

Pressing down the brake pedal (8) 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.

Steering Wheel

Turning the steering wheel (9) to the left or right steers the vehicle in the corresponding direction. Any one of the steering modes are selectable. Refer to “Steering Mode Selector” on page 25.

Horn Button

Pressing the horn button (10) sounds the horn. When the blackout light system is activated the horn will not operate.

Model MMV Rev. 10/11

Operation

OM1780

Ignition Switch

The ignition switch (1) is located on the right side of the lower front dash. The switch may be turned clockwise from the OFF (2) position to the RUN (3) and START (4) positions. To rotate the switch to the START position, push the switch IN and rotate to the START position. 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. ST ART position (4) — Engages st arter motor to crank the engine when the

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

Model MMV Rev. 10/11

Operation

OM1790

786

Steering Mode Selector

Three Mode Steer Select

This vehicle has one steering mode selector (5) located on th e left side of the front dash. The selector has three positions.

• Front Wheel Steer (6).

• Crab Steer (7).

• Four Wheel Steer (8).

Turn the steer mode selector until the notch at the top of the knob points to the desired steering mode selection. You will feel the knob of the selector slip into a detent position for each mode.

Refer to “Steering Modes” on page 79 for detailed information.

Model MMV Rev. 10/11

Operation

OS0121

OS1323

1/2

OU0381

Parking Brake Switch

The Parking Brake Switch (1) has two positions:

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

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

The Parking Brake Switch must be ENGAGED to permit engine starting. A red LED, on the parking brake switch, will indicate the brake is ENGAGED. The parking brake engaged light (2) will illuminate on the front dash panel any time the parking 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.

Model MMV Rev. 10/11

Operation

OH2591

OH2611

OM3630

OFF

Transmission Disconnect Switch

The transmission Disconnect switch (3) is located on the left side of the front dash and has two positions.

• Push the TOP of the rocker switch in to DEACTIVATE the transmission disconnect function.

• Push the BOTTOM of the rocker switch in to ACTIVATE the transmission disconnect function.

With the transmission disconnect activated, when the service brake pedal is applied, the transmission will be disconnected allowing the engine speed to be increased without the need to place the transmission shifter in the (N) NEUTRAL.

This feature eliminates the need to shift the trans mis sio n to the (N) NEUTRAL before operating the hydraulic system at high engine speed. When the transmission disconnect is active, the drivetrain is disconnected and the hydraulic system has full engine power.

IMPORTANT! W ith the disconnect feature active and the service brake pedal being released, the transmission will be reconnected in the same gear and direction of travel as when it was originally disconnected. The service brakes must remain fully applied for this feature to be functional.

Battery Disconnect Switch (S/N MV1210 & After)

The battery disconnect switch (1) is located in the engine compartment.

This switch, when turned to the "OFF" position, disconnects the circuit between the batteries and the electrical syste m . The ba ttery disconnect switch should be turned to the "OFF" position during periods of ext ended storage.

Model MMV Rev. 10/11

Operation

0000000

RPM X 100

1/2

104

176

248

120

°C

°F

r/min

N D

OM1800

OT0570

OT0580

Neutral Lock Lever

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

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

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

N = NEUTRAL LOCK ..................all the way LEFT

D = DRIVE......... ... .......................all the way RIGHT

Model MMV Rev. 10/11

Operation

OS0340

OM1810

Travel Select Lever

The Travel Select Lever (3) has three positions to select direction of travel:

F = FORWARD (4)......... all the way UP

N = NEUTRAL (5) .......... CENTER position

R = REVERSE (6)...........all the way DOWN

To change travel selections, move the lever UP or DOWN to the desired selection.

When the Travel Select Lever is shifted to REVERSE, the back-up alarm will automatically sound. When the blackout light system is activated the back-up alarm will not operate.

NOTE: The Travel Select Lever must be in the (N) NEUTR A L po sit ion to permit engine starting.

Model MMV Rev. 10/11

Operation

1st

4th

3rd

2nd

OM1820

Gear Select Lever

The Gear Select Lever (1) has a twist grip handle with four positions. Vehicles have four forward gears and three reverse gears.

NOTE: When traveling up a slope, shift to a lower gear as appropriate to avoid “lugging” the engine.

Use first gear for highest torque and pulling power. Use higher gears for higher ground speed. The recommendations listed in the “Load Capacity To Travel Speed Tables” begining on page 94 a re guidelines only. Always use good judgement when traveling with a load.

Model MMV Rev. 10/11

Operation

OS2120

OM1830

Attachment Tilt Mode Switch

The Attachment Tilt Mode Switch (2) ha s two positions which allow the operator t o chose between the Lift/Lower function and the Extend/Retract function accompanying the Attachment Tilt capability. For detailed information, see “Multi-Function Joystick Operation” starting on page 32.

Model MMV Rev. 10/11

Operation

OM1880

Multi-Function Joystick Operation

The joystick (1) is equipped with four buttons that enable the joysti ck to operate in three specific modes. The joystick controls boom movement, attachment tilt and frame sway control.

The logic panel (2) (located in front of the joystick) will illuminate the specific mode that corresponds with the movement of the joystick (1) and the selected buttons.

Two functio ns can be accomplished at the same time by mo ving the joystick in between quadrants. For example; in Mode 1, moving th e joyst ick forward and to the left will lower and retract the boom simultaneously.

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

IMPORTANT! Be aware that joystick modes will change immediately

upon depressing or releasing of any button when the joystick is in an off-center position.

Model MMV Rev. 10/11

Operation

OS0600

OM0660

Mode 1

Boom Control (Default)

(No buttons depressed) This mode is accomplished by using the multi-function joystick (3) without

depressing any of the buttons. All four function lights will illuminate on the logic panel (4).

Boom Lift............................... move handle backward

Boom Lower.......................... move handle forward

Boom Extend .........................move handle to the right

Boom Retract.........................move handle to the left

Model MMV Rev. 10/11

Operation

OM1830

For the attachment tilt mode covered in Mode 2A and 2B on the following pages, use the attachment tilt mode switch (1) locate d in the upper bank of switches to the right of the steering wheel.

Model MMV Rev. 10/11

Operation

OM0670

OS0671

OM0680

Mode 2A

Attachment Tilt Up/Down & Boom Extend/Retract

(Right button depressed) Press the top of the attachment tilt mode

switch in.

Press and hold the right button (2) on the top side of the muti-function joystick (3). As the mode is activated the corresponding lights will illuminate on the logic panel (4).

Attachment Tilt Up................. move handle backward

Attachment Tilt Down............ move handle forward

Boom Extend .........................move handle to the right

Model MMV Rev. 10/11

Boom Retract.........................move handle to the left

Operation

OM0690

OS0610

OM0700

Mode 2B

Boom Lift/Lower & Attachment Tilt Up/Down

(Right button depressed) Press the bottom of the attachment tilt

mode switch in.

Press and hold the right button (1) on the top side of the muti-function joystick (2). As the mode is activated the corresponding lights will illuminate on the logic panel (3).

Boom Lift ...............................move handle backward

Boom Lower ..........................move handle forward

Attachment Tilt Down ............move handle to the right

Attachment Tilt Up.................move handle to the left

Model MMV Rev. 10/11

Operation

OS0611

OM0710

Mode 3

Boom Lift/Lower & Frame Sway Right/Left

(Depress left & front buttons simultaneously, then hold eith er button) This mode is accomplished by using the multi-function joystick (4) and

depressing the front (5) and left (6) buttons simultaneously, then while holding either button, move the joystick to the required function. As the mode is activated the corresponding lights will illuminate on the logic panel (7).

Boom Lift............................... move handle backward

Boom Lower.......................... move handle forward

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

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

Model MMV Rev. 10/11

Operation

OM0880

OM1880

Fork Shift Control Switches

The left (1) and right (2) fork shift switches shift the individual forks on the carriage to the left or right. The rocker switches are spring loaded to return to the center (stop) position when released.

Left Fork, Shift to the Left ..............press top of left switch

Left Fork, Shift to the Right............press bottom of left switch

Right Fork, Shift to the Left............press top of right switch

Right Fork, Shift to the Right..........press bottom of right switch

Seat Belt

Always wear the seat belt when operating the vehicle. The seat belt has one retractable strap (3) for easy installation and removal. Insert the seat belt tang into the receptacle (4) to fasten. Press the center red button ( 5) to unfasten the seat belt.

Model MMV Rev. 10/11

Operation

OM1840

WARNING: Serious bodily injury or death 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 operators 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 of the belt into the receptacle end of the belt.

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

4. To release the belt latch, depress the red button (5) an d pull the free end (3) from the buckle (4).

Model MMV Rev. 10/11

Operation

OM1840

Operators Seat Adjustments

The operator’s seat can be adjusted three ways:

Fore and Aft Adjustment

Pull the handle (1) outward to adjust the seat forwar d an d backward. Release the handle to lock the seat in the desired position.

Suspension Adjustment

Turn the knob (2) on the front of the seat to adjust the suspension to correspond with the operator’s weight. Turn clockwise to increase stiffness. Turn counter-clockwise to reduce the stiffness.

Backrest Angle Adjustment

The angle of the seat backrest can be adjusted t o suit th e ope rator. Move the lever (3) located on the left side the seat backrest to adjust the angle.

Model MMV Rev. 10/11

Operation

OM1550

OH2570

OM1830

Interior Cab Light

The interior cab light is located on the top of the cab just behind the operators head. The interior cab light will operate with the ignition switch in the OFF or RUN positions.

The interior cab light is operated with a slide type switch located on the light assembly. To turn the interior light ON, push the switch on the light to the rear ON position. Return the switch to the center OFF position to turn the interior light OFF.

When the blackout light system is activated the interior cab light will not operate.

Worklights

The worklights are activated with a rocker switch (4) located in the upper bank of switches on the right side of the fr ont dash. There are three positions - OFF, Boom Worklight and Boom & Rear Worklights. The lights only work when the ignition switch is in the RUN position and the blackout light system switch is in the OFF position. When the blackout light syste m is activated these lights will not operate.

Model MMV Rev. 10/11

Operation

OS1900

OM1850

Parking Lights, Headlights & High/Low Beam Switch

With the ignition switch ON use the turn signal switch (1) to control the high/low beam headlights, turn ON the parking lights and the headlights. Turn the twist grip end (2) of the turn signal switch counter-clockwise to the first position (3) to turn the parking lights ON. Turn the twist grip to the second position (4) to turn the headlights and parking lights ON. Turn the twist grip clockwise to the OFF position (5) to turn all the lights OFF. Pull the turn signal switch toward you to switch from low beam to high beam. When the hig h bea m is ON the high beam indicator light on the front dash panel will illuminate. When the blackout light system is activated these lights will not operate.

Model MMV Rev. 10/11

Operation

OM0840

OM0850

OM1830

Blackout Light System Activation Switch

The blackout light system activation switch (6) is a rocker switch, located in the upper bank of switches on the right side of the front dash. This switch has two positions system ON and system OFF. This switch must be in the ON position and the ignition switch in the RUN position before the blackout driving lights or marker lights can become functional.

Blackout Drive/Marker Lights

This switch (7) is located in the upper bank of switches on the right side of the front dash. The blackout light system activation switch must be in the ON position. The blackout drive/marker switch has two positions:

Drive/Marker Lights ON ..................Press bottom of switch

Marker Lights Only ON ...................Press top of switch

Model MMV Rev. 10/11

Operation

OS1910

OS1920

OM1860

Directional Signals

The directional signals are activated from the lever (1) on the right side of the steering wheel. To activate the left turn signal (2); raise the lever. To activate the right turn signal (3); lower the lever. To dea ctivate either directional signal, the lever must be manually returned to the center position. The lever will not cancel automatically after a turn. When the blackout light system is activated the directional signals will not operate.

Emergency Flashers

To activate the emergency flashers; push the emergency flashers switch (4) located on the front dash to the right of the steering wheel. When the blackout light system is activated the emergency flashers will not operate.

Model MMV Rev. 10/11

Operation

OU1190

Door Latches

There are two door latches. The outside latch (5) is a pull-to-relea se type. The inside latch (6) is also a pull-to-release latch.

Door Window Latch

The door window (7) can be swung open by releasing the window from inside the cab. Release the window from the door with the window latch handle (8). Pivot the handle out of the way and swing the window open. Swing the window all the way open and lock in place on the outside of the cab. The window can be released from inside the cab using the window release located on the inside of the cab or from the outside, using the outside release (9) located on the cab door window. The inside and outside latches are both turn to release locks.

CAUTION: DO NOT operate the vehicle with the door

window swinging free. Damage to the door window could result if door window is not secured in the OPEN or CLOSED position.

The door window must be latched in the OPEN or the CLOSED position during operation of the vehicle.

Model MMV Rev. 10/11

Operation

OU09201

OM2090

Rear Window Latch

The rear window (1) can be partially opened and secured in place with the rear window latch. To open the window , grab the latch ha ndle (2) and pull up and then push the window outward. To close and secure the window, pull the latch handle up and then inward.

NOTE: In an emergency situation, the operator can exit through the rear window opening by removing the latch pin (3) on the window la tch. The window is then free to swing open.

Rifle Mount

Stow rifle in stowage mount as follows:

• Position butt of M-16 rifle in the lower mount (4) with trigger guard forward.

• Position barrel of M-16 rifle in upper mount (5).

• Check that M-16 rifle is held tightly.

Remove rifle from stowage mount as follows:

• Pull the handle of the upper mount (5) to the side.

• Remove the barrel of M-16 rifle from the upper mount.

• Remove the butt of M-16 rifle from the lower mount (4).

Model MMV Rev. 10/11

Front Windshield Wiper

OS19301

OH2591

OH2601

OH2611

OM1830

The three position front wiper switch (6) is located in the lower bank of switches to the right of the steering wheel. this single rocker switch controls the speed of the front windshield wiper.

• Push the TOP of the rocker switch in to turn the front wiper OFF.

• Place the rocker switch in the MIDDLE position to operate the wiper at LOW speed.

• Push the BOTTOM of the rocker switch in to operate the wiper at HIGH speed.

Operation

Model MMV Rev. 10/11

Operation

OS19401

OH2591

OH2611

OM1830

Windshield Washer Control

This rocker switch (1) is spring loaded to return to the OFF position when released. This switch is located in the lower bank of switches to the right side of the steering wheel.

• Release the switch to deactivate the washer control.

• Press and hold the BOTTOM of the r ocker switch in to activate the windshield washer. The rocker switch is spring loaded and will return to the OFF position when released.

Model MMV Rev. 10/11

Operation

OS2100

OM1520

OH2591

OH2601

OH2611

OM1530

OU0170

Skylight Wiper/Washer & Rear Window Washer

The skylight (roof) wiper/washer switch and rear window washer (2) is located in the lower bank of switches to the right of the steering wheel. It controls the skylight wiper, skylight washer along with the rear window washer. When the skylight washer is activated, the rear window washer is also activated.

• Push the TOP of the rocker switch in to turn the skylight (roof) wiper OFF.

• Place the rocker switch in the MIDDLE position to turn the skylight (roof) wiper ON. This wiper is a single speed wiper.

• Push and hold the BOTTOM of the rocker switch to activate the skylight (roof) and rear window washers. The rocker switch is spring loaded and will return to the skylight (roof) wiper, ON position, when the washer position is released.

Rear Window Wiper

The rear window wiper rocker switch (3) is located on the motor housing of the rear wiper.

The switch has two positions; wiper ON (4) and wiper OFF (5).

Model MMV Rev. 10/11

Operation

OS1950

OS1960

OM1830

Cab Heater/Air Conditioning Controls

The cab heater and air conditioning controls (1) are located next to the lower bank of switches on the right side of the front dash. From left to right the control panel consists of: a variable speed fan con tr ol kn ob (2), an A/C on-off rocker switch (3) and a temperature control knob (4).

Control of air flow is made by opening, closing or redirecting the air vent louvers in four seperate locations inside the cab. For instance, if the front glass needs rapid defrosting, red irect the air flow at the front two vents (directing the vent louvers toward the glass) and close the remaining two vents. This will increase the volume of air flow to the front glass and speed defrosting.

Model MMV Rev. 10/11

To heat the cab:

OS1950

OA1390

OS1960

OU0930

• turn A/C rocker

switch (3) to the OFF position,

• turn temperature control knob (4) to far right position

(RED = HOT),

• direct desired air flow by adjusting vent louvers,

• turn fan control (2) to “3” (5) to assure rapid warm-up.

To defrost the cab:

• turn temperature control

knob (4) to the far right position (RED = HOT),

• direct desired air flow by adjusting vent louvers,

• turn fan control (2) to “3” (5) to assure rapid defrost.

To cool the cab:

• turn A/C rocker switch

(3) to the ON position,

• turn temperature

control knob (4) to the far left position (BLUE = COOL),

• direct desired air flow by adjusting vent louvers,

Operation

• turn fan control (2) to “3” (5) to assure rap id cool-down.

Model MMV Rev. 10/11

Operation

OM2100

OH3290

Cab Circulation Fan

The cab circulation fan (1) is located at the top right side of the cab just above the operators seat. The fan has a three position toggle switch (2) located on the fan mount. The fan can be operated at HIGH speed (switch down) or LOW speed (switch up). The fan can be swive led to direct the flow in the desired direction.

Engine Function Indicator Lights

The engine function indicator lights (3) are located in the switch bank on the left side of the front dash. The light indicates any faults that arise in the engine during operatio n. The light contains a RED light (4) and a AMBER light (5).

If the RED light (4) comes ON during operation, STOP IMMEDIATELY

and diagnose the fault by activating the ECM

diagnostic system. Activate the system with the accelerator pedal.

the engine

Activate the system and read the code as indicated by the RED light (4). 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 1-800-34 3-7357.

If the AMBER light (5) 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.

Model MMV Rev. 10/11

Activate the system and read the code as indicated by the light.

OM1870

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

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.

Operation

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 MMV Rev. 10/11

Operation

0000000

RPM X 100

1/2

104

176

248

120

°C

°F

r/min

OU0010

Front Dash Panel

The front dash panel (1) provides the operator wit h important information. It is “user friendly” and only provides the oper ator with the inf ormation needed at any given time.

Front Dash Panel Light Test

To test the front dash panel lights; turn the ignition switch to the RUN position, ALL the lights (13 total) will come ON for three seconds as a test function. During this time an audible alarm will sound. Replace any bulbs that DO NOT come ON during this test.

Do not forget to refasten your seat belt before operation. Always wear the seat belt when operating the vehicle.

Model MMV Rev. 10/11

Operation

OH2260

OS1970

OU0050

OU0040

Function Indicator Lights

There are four “hidden” function indicator lights in the front dash panel that illuminate only when a specific function has been activated. They are:

Parking Brake Indicator (2)

This light illuminates any time the parking brake is applied and the ignition switch is in the RUN position.

Stabil-TRAK Mode Indicator Lights (3 & 4)

One of these lights will illuminate when the Stabil-TRAK system has been ACTIVATED in the “Locked” Mode (3) or the “Slow Pivot” Mode (4). Refer to “Understanding the Stabil-TRAK™ System” on page 73 for a detailed explanation.

Engine Air-Intake Heater Indicator (5)

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 eng ine is read y to star t.

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 MMV Rev. 10/11

Operation

OT0990

OT1000

OT1010

Warning Indicator Lights

There are seven additional “hidden” indicator lights in the front dash panel that will illuminate during critical circumstances. all seven warning indicator lights demand immediate attention and vehicle servicing. In many cases, the vehicle should be shut down AS SOON AS PRACTICAL serious mechanical failure.

The warning indicator lights are:

Transmission Temperature Warning Indicator (1)

This light illuminates when the transmission oil temperature is too high; above 250° F (121° C). An audible alarm will also sound. Stop and idle the vehicle with the transmission in (N) Neutral, allowing time for cooling. If the light does not go out after two minutes, shut the vehicle down.

Hydraulic Oil Temperature Warning Indicator (2)

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

Engine Oil Pressure W arning Indicator (3)

to prevent

This indicator light will come ON if the engine is not started. This is normal. If the light comes ON while the engine is running, this indicates that the engine oil pressure is t oo lo w. When the engine is running an audible alarm will also sound when the low oil pressure light is ON. SHUT THE VEHICLE DOWN AS SOON AS PRACTICAL.

Model MMV Rev. 10/11

Alternator Charging Warning Indicator (4)

OH2560

OT1020

OT1030

0000000

RPM X 100

1/2

104

176

248

120

°C

°F

r/min

OU0010

This light illuminates to indicate a weak or improperly working charging system or the batteries are dead. Service the engine alternator or batteries.

Engine Air Filter Restriction Warning Indicator (5)

This light illuminates when a restricted engine air filter is detected. If the light is ON, service the air filter(s).

Hydraulic Oil Filter Restriction Warning Indicator (6)

This light illuminates when a restricted hydraulic oil filter is detected. If the light is ON, service the hydraulic oil filter.

Operation

Model MMV Rev. 10/11

Operation

OM1600

0000000

RPM X 100

1/2

104

176

248

120

°C

°F

r/min

OU0010

Low Brake Pressure Warning Indicator (1)

This light is located on the lower right side of the front dash panel.

The light will come ON and the buzzer sounds when service brake hydraulic system pressure drops below the safe operating level. Under normal conditions, the light and buzzer will go out quickly after engine start. If the light or buzzer does not go out or comes ON during vehicle operation, shut off engine immediately, investigate, and repair before operating. DO

NOT operate vehicle when low brake pressure light or buzzer is on.

WARNING: Operating the vehicle with the service

brake system malfunctioning will cause reduced braking ability or no braking ability when the service brake pedal is depressed. Death or serious personal injury could result from the inability to stop or slow the vehicle.

If the low brake pressure light or buzzer remains ON, place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the parking brake switch and turn the engine OFF.

Have the service brake system serviced before using the vehicle again. Contact your local JLG Authorized Service Center (ASC) immediately to repair the system.

Model MMV Rev. 10/11

Gauges and Indicators

OH24701

r/min

OU0020

OU0030

OT0980

Fuel Level Gauge (2)

Make sure the vehicle is level to ensure an accurate fuel level reading. The fuel gauge located on the left side of the front dash panel, indicates the amount of fuel in the fuel tank. Refuel before the fuel gauge reaches the “E” to prevent running out of fuel. Capacit y o f th e fu el tan k is 50 . 2 gallo ns (190 liters) total capacity with a usable capacity of 45 gallons (171 liters). If the engine ever runs out of fuel, the fuel system will need to be bled. Refer to “Bleeding Fuel System” page 160.

Engine Tachometer (3)

The tachometer is the gauge in the center of the front dash panel and indicates speed of the engine in revolutions per minute (rpm).

Hourmeter (4)

The hourmeter records engine operating hours and has a total readout of 99,999.99 hours. It is located on the front dash panel in the lower portion of the tachometer.

Operation

Engine Coolant Temperature Gauge (5)

The engine coolant temperature gauge is located on the right side of the front dash panel. Glance at the gauge on a regular basis during operation. The gauge monit ors the temperature at which the engine is operating. If the gaug e goes over 210° F (99° C) the engine coolant is too hot. Idle the en gine for 1 minute prior to shutting the vehicle down. If the radiator is boiling over, SHUT THE VEHICLE DOWN AS SOON AS PRACTICAL.

Model MMV Rev. 10/11

Operation

OS1900

OH2510

0000000

RPM X 100

1/2

104

176

248

120

°C

°F

r/min

OU0010

Additional Indicator Lights

There are two additional “hidden” indicato r lights in the front dash panel that will illuminate only when the road lights are activated.

High Beam Indicator (1)

Whenever the headlights are on “high” beam this light will illuminate and remain ON until the headlights are switched to “low” beam.

Turn Signal Indicator (2)

The turn signal indicator light will illuminate and flash when the turn signals are activated in either direction or when the hazard lights have been activated.

Model MMV Rev. 10/11

Operation

OS0232

OM0961

Instruments and Indicators

Frame Level Indicator

The frame level indicator (3) is mounted on the top inside of the cab. It 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.

Boom Angle Indicator

The boom angle indicator is a plumb arrow (4) with angular graduations (5) from -10° to + 80°. It is located on the left side of the boom (6) and is visible from the operators position. Use this indicator to dete rmin e the b oom ang le when reading the capacity chart (see “Using the Capacity Chart” on page 92).

Model MMV Rev. 10/11

Operation

OS1470

OM1670

Rear View Mirrors

Three rear view mirrors are provided to aid the operator’s rear visibility. The mirrors are adjustable and need to be adjusted to obtain the best rear view possible for the operator. There is one mirror (1) on the left front side of the cab and a second mirror (2) inside the cab in the upper right front corner. The third mirror (3) is located on the side of the engine ho od.

Model MMV Rev. 10/11

Operation

Load Moment Indicator

WARNING: The Load Moment Indicator (L M I) system

is not intended to be an absolute charts. DO NOT exceed rated capacities! Any attempt to lift or carry loads in excess of those shown on the capacity chart may cause vehicle tipover, loss of load or structural damage which could result in death or serious personal injury.

The load moment indicator is a feature which continually monitors the load on the rear axle as loads are being lifted and extended. The system alerts the operator when the ground pressur e on the rea r of the ve hic l e ha s decreased to a point that the rear of the vehicle could raise up off the ground. This system indicates the level of forward stability and not necessarily of sideways stability. The display panel (4) is mounted in front of the joystick on the right side console.

1. The display has a green power light (5) next to the te st button (6) to inform the operator that the system is active. This light will come ON when the ignition is turned to the RUN position.

2. The display has a series of three green lights (7), one amber light (8), one red light (9) and an audib l e a lar m tha t inf orms t he op er ator of each operating load range.

3. As the load is extended and reaches 100% of the vehicles capacity, the three green lights will be lit and the amber light will flash.

replacement for the capacity

4. As the load goes over 100% of the vehicles capacity the red light will come ON and an audible alarm will sound, alerting the operator that the load should be retracted.

Model MMV Rev. 10/11

Operation

100%

TEST

OM1890

Model MMV Rev. 10/11

Operation

100%

TEST

OM1890

Load Moment Indicator System Test

ALWAYS

Changing Display Settings

The display has muting and dimming settings which allow the operator to set the level of brightness and the sound level of the alarm. There are four possible combinations.

To change the settings, PRESS and HOLD the test button (1) continuously while the display sequences through each combination. Release the test button when the preferred combination occurs. The combinations are:

test the LMI system before starting to work with a load.

1. Turn the ignition to the RUN position.

2. Momentarily press the test button (1) on the load moment indicator display (2). ALL the lights should flash ON and the audible alarm will sound. This will tell you that the display is functioning properly.

• Full Brightness with Full Volume

• Full Brightness with Muted Volume

• Dim Brightness with Full Volume

• Dim Brightness with Muted Volume

Model MMV Rev. 10/11

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 ot her 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 152.

4. Check and add transmission oil if required. This procedure is explained in greater detail on page 169.

5. Check the cooling system overflow bottle for coolant. Add coolant if required. This procedure is explained in greater d etail on page 148. 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 164.

7. Visually inspect the batteries for cleanliness. Check terminals for corrosion. Check the cable connections to ensure prop er tightne ss.

8. (S/N MV1210 & After) Make sure the battery shut-off switch in the engine compartment is in the "ON" position.

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

10. Perform the LMI system test. Refer to “Load Moment Indicator System Test” on page 65.

11. Check ALL lighting systems for proper operation.

12. Adjust rear view mirrors as required to obtain proper field of vision to the rear.

13. Test the back-up alarm and horn for proper operation.

14. Check condition of cab glass, looking for cracks or other damage .

15. Visually check the condition of the air conditioner condenser. Remove any debris from the cooling fins of the air co nditioner condenser located at the rear of the frame. Clean the fins as needed.

Model MMV Rev. 10/11

Operation

Normal Starting

1. (S/N MV1210 & After) Make sure the battery shut-off switch in the engine compartment is in the "ON" position.

2. Enter the cab and adjust the seat for comfortable operation.

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

W ARNING: 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.

4. Fasten the seat belt.

5. Make sure the parking brake switch is ENGAGED.

6. Place the travel select lever in (N) NEUTRAL.

7. Move the Neutral Lock Lever to the (N) NEUTRAL LOCK Position.

8. Push and turn the ignition switch to the START position (fully clockwise) to crank the engine. Release the ignition switch when the engine starts. If the engine fails to start on t he first try, wait until th e engine and starter come to a complete stop before cranking the engine again.

IMPORT ANT! DO NOT crank t he start ing mo tor continu ously for mo re than 30 seconds. Stop cranking the starter and allow the starter to cool for 2 minutes before engaging the starter again.

9. After the engine starts, run engine at partia l throttle f or 30 to 60 seconds before operating the vehicle. Return to idle before engaging the travel or range select levers.

10. Move the Neutral Lock Lever to the (D) DRIVE Position before you start operating.

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

Model MMV Rev. 10/11

Operation

Cold Starting

The engine is equipped with a 120 volt 750 wat t 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 sys-

tem 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 ma nifold. 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 55) will illuminate on the front dash panel. DO N OT turn the ignition switch to START until the air-intake 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.

W ARNING: 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.

Model MMV Rev. 10/11

Operation

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.

IMPORT ANT! DO NOT crank t he start ing mo tor continu ously for mo re 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.

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.

Model MMV Rev. 10/11

Operation

OM3640

Slave Starting

WARNING: To avoid death or serious personal injury,

never slave start the vehicle with 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 nea r batt eries.

This vehicle is equipped with a 24 volt, negative ground electrical system. The NATO slave receptacle (1) is located under the eng ine co ve r in fr ont of the transmission. Ensure that both the disabled and booster vehicle are equipped with a NATO slave receptacle.

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

2. Connect the other end of the NATO slave cable to the disabled vehicle NATO slave receptacle.

3. Run the booster vehicle at a speed just above idle.

4. Follow the steps in “Normal Starting” on page 67.

5. After starting the disabled vehicle, return the booster vehicle to idle.

6. Remove the NATO slave cable from the disabled vehicle first and then from the booster vehicle.

Model MMV Rev. 10/11

Operation

OS0860

Refueling

Make sure the vehicle is level to assure an accura te fuel level reading. The fuel tank is capable of holding 45 gallons (171 liters) of diesel fuel.

Fuel Types

The preferred fuel is 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.

W ARNING: Engine fuel is flammable and can ca use a

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

Alternate Fuel Types

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

Model MMV Rev. 10/11

Operation

OM1900

Fuel Cap

The fuel cap (1) is conveniently located on the left side of the vehicle. The fuel cap meets EPA standards.

To remove the fuel cap:

1. Level the vehicle, ground the attachment, place the travel select lever in (N) NEUTRAL, move the neutral lock lever to the (N) NEUTRAL LOCK position, engage the parking brake switch and turn the ignition switch to the OFF position.

WARNING: REMOVE FUEL CAP SLOWLY. Fuel

spray may cause personal injury. Fuel can spray out on you if

you open the cap too quickly or if you fill the tank too rapidly.

2. Slowly turn the cap in a counter-clockwise rotation. Wait for any “hissing” noise to stop. THEN unscrew the cap all the way and remove the cap from the filler neck.

To install the fuel cap:

Turn the cap clockwise until the cap bottoms on the filler neck. The fuel cap is now properly installed.

Model MMV Rev. 10/11

Operation

OS1970

0000000

RPM X 100

1/2

104

176

248

120

°C

°F

r/min

OM1910

Operating

Understanding the Stabil-TRAK™ System

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 control will function normally. Both Stabil-TRAK lights on the front dash panel will be OFF (3).

Model MMV Rev. 10/11

Operation

0000000

RPM X 100

1/2

104

176

248

120

°C

°F

r/min

OM1920

Locked Mode

With the boom above 40° (4) and by activating one o r more of the fu nctions (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 lock light on the front dash panel will be ON (6). The Stabil-TRAK slow pivot light on the front dash panel will be OFF (7).

• Engaging the parking brake switch

• Placing the travel select lever in (N) NEUTRAL

• Depressing and holding the service brak e pe d al

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

Model MMV Rev. 10/11

Operation

0000000

RPM X 100

1/2

104

176

248

120

°C

°F

r/min

OM1930

Slow Pivot Mode

With the boom above 40° (1), the Stabil-TRAK Syst em 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 slow pivot light on the front dash panel will be ON (3). The Stabil-TRAK lock light on the front dash panel will be OFF (4).

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

test procedure on page 237 for the proper system function.

to changes in terrain. The Stabil-TRAK

Model MMV Rev. 10/11

Operation

OM1810

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 to 1st gear.

3. Move the travel select lever (5) to (F) FORWARD (6) to travel in a forward direction or to (R) REVERSE (7) to travel backward.

4. Slowly remove your foot from the service brake ped al 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 (5), pull it toward the steering wheel, then move the lever up or down in the opposite direction; (R) REVERSE (7) or (F) FORWARD (6).

Model MMV Rev. 10/11

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 list ed in the “Load Capacity To Travel Speed Tables” begining on page 94 are guidelines only. Always use good judgement when traveling with 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.

Model MMV Rev. 10/11

Operation

0000000

RPM X 100

1/2

104

176

248

120

°C

°F

r/min

N D

OM1800

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

Model MMV Rev. 10/11

Operation

OM1790

342

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.

This vehicle has one steering mode selector (1) located on th e left side of the front dash. The selector has three positions.

• Front Wheel Steer (2).

• Crab Steer (3).

• Four Wheel Steer (4).

Turn the steer mode selector until the notch at the top of the knob points to the desired steering mode selection. You will feel the knob of the selector slip into a detent position for each mode.

Model MMV Rev. 10/11

Operation

OS0280

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 244 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.

Model MMV Rev. 10/11

Operation

OS0290

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.

Model MMV Rev. 10/11

Operation

OS0310

3. Crab Steering

W ARNING: NEVER use the Crab Steering Mode when

traveling at high speed. Rapid turning in this mode can cause tipover . Use only the Front Whe el Steering Mode at hi gher 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.

Model MMV Rev. 10/11

Maximum Fork Sweep

OS0323

OS0232

CAUTION: Allow for adequate clearance between

the attachment and other objects when turning.

The attachment extends beyond ator must be aware of the maximum sweep (1) of the attachment when turning in order to avoid hitting personnel and other objects in the area.

Leveling the Vehicle

Operation

the end of the vehicle. The oper-

When placing a load while on a slope, use the frame sway control (see MODE 3 page 37) to keep the vehicle level. The operator should observe the frame level indicator (2) 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 MMV Rev. 10/11

raising the boom above horizontal. If the vehicle

Operation

OM0970

Carriages

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.

NOTE: Ensure the forks of the carriage being remo ve d ar e in a po sitio n other

than fully shifted inboard or outboard to minimize trapped hydraulic

pressure.

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

2. Extend the boom approximately 10 feet (3 me te rs ) an d tilt th e c arriage backward.

3. Exit the vehicle using both hand holds.

4. Remove the spring clip pin (3) from the quick attach pin (4) and pu ll the pin out of the bottom of the quick att ach link (5).

Model MMV Rev. 10/11

Operation

OM0930

5. Remove the four hydraulic quick disconnects between t he carriage and the vehicle. Remove the disconnects in the following order: Disconnect the RED (1) then the BLACK (2) on the left side. Disconnect the GREEN (3) then the YELLOW (4) on the right side.

6. Install the “Male” and “Female” protective caps (5) on all four quick disconnects.

7. 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.

8. Lower and then retract the boom until the attach m en t pivot pins have disconnected from the attachment.

Model MMV Rev. 10/11

Operation

OM0970

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 me te rs ) an d dr ive 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 ho les in the link and the attachment should be aligned.

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

7. Insert the quick attach pin (6) completely th ro ug h th e at tac hm e nt and the quick attach link (7). Insert the spring clip pin (8) through the quick attach pin.

Model MMV Rev. 10/11

Operation

OM0930

8. Remove the protective caps from the quick couplers. Connect the quick couplers in the following order: Connect the YELLOW (1) then the GREEN (2) on the right side. Connect t he BLACK (3) th en the RED (4) on the left side.

9. In the event there is trapped pressure in one of t he carriage hydraulic hoses, connect the quick coupler(s) with a firm constant motion. This will allow the (specially designed) male quick coupler to drain the trapped pressure through to the female coupler and into the hydraulic system.

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

Model MMV Rev. 10/11

WARNING: DO NOT operate this vehicle unless you

are in the seat with the seat belt fastened aroun d you. Death or serious personal injury could result if the belt is not securely fastened.

Operation

OM1940

Transport Position - 11K Fork Carriage

Loading the 11K Carriage for Transport

Your vehicle will arrive with its 11K carriage (5) riding on the attached 7K carriage (6). You must remove and store the 1 1K carriage if the 7K carriage is to be used. Or, if the 11K carriage will first be placed in service, you will remove the 11K carriage and store the 7K carriage, and then reattach the 11K carriage to the vehicle.

The aid of an assistant will be required to perform this task, because the proximity of the 11K carriage alignment to the 7K carriage will be difficult to determine from inside the cab.

Model MMV Rev. 10/11

Operation

OM1880

Removing the 1 1K Carriage from the 7K Carriage

1. Use the right fork shift switch (1) to move the right fork on the 7K carriage to the right, just enough for the back of the right fork to clear the weldment on the back of the 1 1K carr iage. Use the left fork shift switch (2) to move the left fork on the 7K carriage to the left, just far enough for the back of the left fork to clear the other weldment.

2. Ensure that the 11K carriage is positioned on a level surface for proper storage.

3. Lower and level the 7K carriage until the 11K carriage just rests on the ground.

4. Back the vehicle up until the 7K carriage forks are clear of the unloaded 11K carriage.

Model MMV Rev. 10/11

Operation

OM1241

Installing the 11K Carriage on the 7K Carriage

IMPORTANT! Before installing the 11K carriage on the 7K carriage place the four hoses (3) from the rear of the 11K carriage up and over the top of the carriage. This will ensure that the hoses do not get pinched by the 7K carriage during installation of the forks for tr ansport of the 11K carriage. Pull the hoses toward the front of the carriage to remove all the slack fr om the hoses. Let all four hoses hang down in front of the 11K carriage.

1. Ensure that the 11K carriage forks (4) are inboard of the openings (5) in the carriage back for the 7K carriage forks to be inserted through. If the 11K carriage forks interfere, attach the 11K carriage, close the fork gap and remount the 7K carriag e.

2. Maneuver the vehicle so the 7K carriage is centered on the 11K carriage.

3. Lower the 7K carriage so the forks are at the same he ig ht fr om the ground as the openings (5) in the 11K carriage.

4. Maneuver the vehicle so the 7K carriage forks (6) go in the intended openings (5) in the 11K carri age. The b ack of th e 11K carriage must be resting against the vertical area of the 7K forks.

Model MMV Rev. 10/11

Operation

OM1880

5. Use the right fork shift switch (1) to move the right fork on the 7K carriage to the left, enough for the back of the right fork to rest tightly against the weldment on the back of the 11K carriage. Use the left fork shift switch (2) to move the left fork on the 7K carriage to the right, enough for the back of the left fork t o rest tightly a gainst the other weldment.

6. Place the travel selector in NEUTRAL (N) and engage the parking brake.

7. Exit the operators compartment and visually confirm that both 7K forks are fully engaged behind the weldments on the back of the 11K carriage.

8. Raise the boom and the 7K carriage into the travel position. The 11K carriage can now be transported.

Model MMV Rev. 10/11

Operation

OM1950

Using the Capacity Chart

The individual capacity charts are located inside a booklet (3) on the right side of the operator’s compartment. 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. Choose the correct load chart for the size carriage being used and the tire pressu re being utilized.

Model MMV Rev. 10/11

Operation

OM1960

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 (1)

• boom angle indicator (2)

As the boom is extended, boom extend letters (1) and vertical dividin g lines (3) become visible on the left side of the intermediate boom (4). These letters and vertical lines indicate the point (zone) of boom extension and correspond to the capacity chart. For example, when the boom extend “B” first appears, the boom is at the point of boom extension corresponding to an arc of line “B” on the capacity chart.

The boom angle indicator (2), located on the left side of t he outer boom, 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

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

tires.

IMPORTANT! If operating the vehicle at 60 psi (414 kPa) or 45 psi (310 kPa) reduced tire pressures, refer to “Load Capacity To Travel Speed Tables” begining on page 94 for proper operating capacities and speeds. ALWAYS refer to the proper load chart in the operators cab when working with a load.

Model MMV Rev. 10/11

Operation

OM2260

Load Capacity To Travel Speed Tables

Use With 87 psi (600 kPa) - Full Tire Pressure

Recommended Gear/Speed for Various Load/Travel Conditions

(Forward Direction Only)

7 K Fork Carriage

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 3,500 lbs Improved 2nd 0 to 6 mph (0 to 9,7 km/h)

(up to 1.588 kg)

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

3,500 to 7,000 lbs Improved 2nd 0 to 6 mph (0 to 9,7 km/h)

(1.588 to 3.175 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)

11 K Fork Carriage

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

4,500 to 11,00 0 lbs Improved 2nd 0 to 6 mph (0 to 9,7 km/h) (2.041 to 4.989 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 MMV Rev. 10/11

Operation

OM2250

OM2320

Use With 60 psi (414 kPa) - Reduced Tire Pressure

Recommended Gear/Speed for Various Load/Travel Conditions

(Forward Direction Only)

7 K Fork Carriage

Load Size Surface Gear Speed

No Load Smooth 3rd 0 to 14 mph (0 to 23 km/h)

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

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

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

(up to 907 kg)

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

(907 to 1.814 kg)

Load Size Surface Gear Speed

No Load Smooth 3rd 0 to 14 mph (0 to 23 km/h)

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

(up to 907 kg)

2,000 to 5,500 lbs Improved 2nd 0 to 6 mph (0 to 9,7 km/h)

(907 to 2.495 kg)

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

11 K Fork Carriage

Improved 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 operating at this tire pressure.

Model MMV Rev. 10/11

Operation

OM2250

OM2320

Use With 45 psi (310 kPa) - Reduced Tire Pressure

Recommended Gear/Speed for Various Load/Travel Conditions

(Forward Direction Only)

7 K Fork Carriage

Load Size Surface Gear Speed

No Load Improved 2nd 0 to 6 mph (0 to 9,7 km/h)

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

Up to 1,000 lbs Improved 2nd 0 to 6 mph (0 to 9,7 km/h)

(up to 454 kg)

Load Size Surface Gear Speed

No Load Improved 2nd 0 to 6 mph (0 to 9,7 km/h)

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

(up to 907 kg)

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

11 K Fork Carriage

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

NEVER travel in 3rd or 4th gear when operating at this tire pressure.

Model MMV Rev. 10/11

Skytrak MMV Owner's/operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Revision Log

Introduction

The Manual

Replacement Parts

Reports

Safety Practices

Disclaimer

Hazard Classification System

Accident Prevention Tags

New or Additional Operators

Instructional Symbols

Hazard Symbols

Avoidance Symbols

Avoidance Symbols (cont’d)

Personal Considerations

Operational Considerations

Equipment Considerations

Operation

Operator Controls

Front Dash Panel

Instruments and Indicators

Pre-Operation Inspection

Normal Starting

Cold Starting

Slave Starting

Refueling

Operating

Carriages

Using the Capacity Chart

Load Capacity To Travel Speed Tables