JLG SkyTrak MMV (Tier 2) Model Telehandler ANSI Repair Service Manual

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This service manual PDF download for the MMV (Tier 2) Model JLG SkyTrak Telehandler has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

JLG SkyTrak Telehandler 
Model MMV (Tier 2)
(S/N: MV201 & After)


TABLE OF CONTENTS :

    Section 1 Safety Practices
    Section 2 General Information, Specifications and Maintenance
    Section 3 Boom
    Section 4 Cab and Covers
    Section 5 Axles, Wheels and Tires
    Section 6 Transfer Case and Drive Shafts
    Section 7 Transmission: ZF 4 WG-98 TS
    Section 8 Engine: Cummins QSB4.5T
    Section 9 Hydraulic System
    Section 10 Electrical System
    Section 11 Stabil-TRAK™ System
    Section 12 Index


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 8990505
Total Pages : 734


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    Effectivity
    TOC
    Section 1 Safety Practices
        1.1 Introduction
        1.2 Owners/Operators Manual
        1.3 Training Mechanics as Operators
        1.4 Safety Information
            1.4.1 Safety Alert Symbol
            1.4.2 Hazard Statements
        1.5 Accident Prevention Tag Usage
        1.6 Safety Instructions
            1.6.1 Personal Hazards
            1.6.2 Equipment Hazards
            1.6.3 General Hazards
            1.6.4 Operational Hazards
        1.7 Emergency Exit Rear Window
        1.8 Hazard/Emergency Information Signs
        
    Section 2 General Information, Specifications and Maintenance
        2.1 MMV Component Terminology
        2.2 Introduction
            2.2.1 Service Methods
            2.2.2 The Owners/Operators Manual
            2.2.3 Replacement Parts and Warranty Information
            2.2.4 Disclaimer
        2.3 Torques
            2.3.1 Fasteners
            2.3.2 Bolts and Nuts
            2.3.3 Straight Thread O-ring Fitting (Non-Adjustable)
            2.3.4 SAE Flat Face O-Ring Seal Hydraulic Fittings
                a. Assembly Procedure
                b. Straight O-Ring Boss Fittings To O-Ring Boss Ports
                c. Adjustable (Angle) O-Ring Boss Fittings To O-Ring Boss Ports
                d. Pipe Fittings to Pipe Ports
        2.4 Metric Conversion Factors
            2.4.1 Approximate American to Metric Conversions
            2.4.2 Approximate Metric to American Conversions
        2.5 Specifications
            2.5.1 Vehicle Dimensions
            2.5.2 Vehicle Weights
            2.5.3 Attachment Weights
            2.5.4 Performance Specifications
            2.5.5 Hydraulic Cylinder Performance Specifications
            2.5.6 Electrical System
            2.5.7 Engine Performance Specifications
            2.5.8 Fluid and Lubricant Capacities
            2.5.9 Hydraulic System
            2.5.10 Tires
            2.5.11 Miscellaneous Specifications
            2.5.12 Tamper Proofing
            2.5.13 Fork Ratings
        2.6 Fluids, Lubricants and Capacities
            2.6.1 Axles (Differential Housings)
                a. Axle Lubricants
                b. Axle Capacities
            2.6.2 Wheel Ends
                a. Wheel-End Lubricants
                b. Wheel-End Capacity
            2.6.3 Lubrication Points (Grease Fittings)
            2.6.4 Hydraulic System
                a. Hydraulic Fluids
                b. Hydraulic System Capacity
            2.6.5 Engine
                a. Engine Fluids and Lubricants
                b. Engine Capacities
            2.6.6 Transmission
                a. Transmission Fluid
                b. Transmission Capacity
            2.6.7 Transfer Case
                a. Transfer Case Lubricants
                b. Transfer Case Capacity
            2.6.8 Air Conditioning
                a. Air Conditioning Fluid
                b. Air Conditioning System Capacity
            2.6.9 Drive Shaft Splines
            2.6.10 General Anti-Corrosion
                a. Anti-Corrosion Compound
                b. Anti-Corrosion Need Areas
            2.6.11 Carriage Fork Shafts and Wear Pads
            2.6.12 Paint
                a. Military Paint (CARC)
                b. Black Paint
                c. Gloss Black Paint
                d. Flat Black Silicone High Temperature Paint
                e. The Following Items Shall Not Be Painted
                f. Varnish
            2.6.13 Thread Locking Compound
        2.7 Cleaning
        2.8 Replacement
        2.9 Hoses and Tubes
            2.9.1 Hose and Tube Inspection
            2.9.2 Hose and Tube Installation
        2.10 Bearings
            2.10.1 Bearing Removal
            2.10.2 Bearing Cleaning
            2.10.3 Bearing Installation
        2.11 Pressure Testing and Adjustment
        2.12 After Service Startup and Checks
            2.12.1 After Service Startup
            2.12.2 After Electrical/Electronic Component Service
            2.12.3 After Hydraulic Component Service
            2.12.4 After Brake System Service
            2.12.5 After Fuel System Service
            2.12.6 After Transmission Service or Replacement
            2.12.7 After Tire and Wheel Service
            2.12.8 After Engine Service
            2.12.9 After Boom Service
            2.12.10 After Axle Service
        2.13 Maintenance Instructions
            2.13.1 Maintenance Schedule and Checklist
                a. 10 Hour Intervals
                b. At First 50 Hours of Use
                c. 250 Hour Intervals
                d. 500 Hour Intervals
                e. 1,000 Hour Intervals
                f. 2,000 Hour Intervals
            2.13.2 Air Cleaner
                a. Engine Air Restriction Warning Indicator
                b. Air Cleaner Element: Change
                c. Air Intake System-Inspection
            2.13.3 Closed Cab Air Filters
            2.13.4 Engine Cooling System
                a. Engine Coolant Level Check (10 Hour Intervals)
                b. Drain and Flush the Radiator
            2.13.5 Engine Oil and Filter
                a. Engine Oil Recommendations
                b. Oil Level Check
                c. Oil and Filter Change
            2.13.6 Engine Oil Sample Point
            2.13.7 Engine Fuel System
                a. Drain Water from Fuel-Water Separator/Filter
                b. Change Fuel Filter
                c. In-line Fuel Strainer
                d. Bleeding Fuel System
            2.13.8 Engine Fan Belt & Air Conditioner Compressor Belt
                a. Engine Fan Belt
                b. Air Conditioner Compressor Belt
            2.13.9 Hydraulic System Oil and Filter
                a. Hydraulic Oil Level Check
                b. Hydraulic Oil and Hydraulic Oil Filter Change
            2.13.10 Transmission Oil and Filter
                a. Transmission Oil Level Check
                b. Transmission Oil and Filter Change
            2.13.11 Axle Oil
                a. Axle Oil Level Check
                b. Axle Oil Change
            2.13.12 Brake Disc Wear Check
                a. Front Axle
                b. Rear Axle
            2.13.13 Wheel End Oil
                a. Wheel End Oil Level Check
                b. Wheel End Oil Change
            2.13.14 Transfer Case Oil
                a. Transfer Case Oil Level Check
                b. Transfer Case Oil Change
            2.13.15 Wheels and Tires
                a. Tire Pressure Check
                b. Wheel Lug Nut Torque Check
                c. Replacing Tires
            2.13.16 Emergency Tire Inflation System
                a. Drain Water From Emergency Tire Inflation Tank
                b. Tire Inflation
            2.13.17 Batteries
                a. Batteries Inspection, Testing and Service
                b. Battery Charging
                c. Slave Starting
            2.13.18 Fuse and Relay Replacement
                a. Disconnect Batteries
                b. Fuses and Relay (Fuse Block)
                c. Fuses, Relays and Flasher (Right Side Console)
                d. Cold Start Grid Heater Fuse (Under Engine Cover)
                e. ECM Fuses (Under Engine Cover)
                f. Battery Equalizer Fuses (Under Engine Cover)
                g. Relay and Fuse (Inside Rear Door)
                h. Re-connect Batteries
            2.13.19 Boom Wear Pad Maintenance
                a. Boom Wear Pad Check
                b. Boom Wear Pad Replacement
                c. Boom Wear Pad Lubrication
            2.13.20 Boom Chain Inspection
            2.13.21 Boom Chain Tension & Adjustment
                a. Boom Chain Tension Check
                b. Extend Chain Adjustment
            2.13.22 Chain Lubrication
            2.13.23 Short Term Storage
                a. Before Storing
                b. B. Removing From Storage
            2.13.24 Long Term Storage
                a. Before Storing a Vehicle
                b. Removing Vehicle from Storage
            2.13.25 Counterweight Removal and Reassembly
                a. Removal
                b. Assembly
            2.13.26 Transport
                a. Truck Transportability
                b. Rail Transportability and GIC Clearance
                c. Air Transport, C-17, C141 or C-5 Tiedowns
                d. Air Transport, C-130 Configuration
                e. Marine Transportability
                f. External Transport/Slinging
        2.14 Emergency Operations
            2.14.1 Towing a Disabled Vehicle Short Distances
            2.14.2 Towing a Disabled Vehicle Long Distances
            2.14.3 Boom Lowering and Retracting
        2.15 Parking Brake/Transmission De-Clutch Test Procedures
        2.16 Stabil-TRAK™ System Test
        2.17 Four Wheel Steer Indexing Procedure
        
    Section 3 Boom
        3.1 Boom System Component Terminology
        3.2 Boom System
            3.2.1 Boom System Description
            3.2.2 Boom System Operation
        3.3 Boom Assembly Maintenance
            3.3.1 Fork Side Shift Hose Carrier Assembly Replacement
                a. Fork Side Shift Hose Carrier Assembly Removal
                b. Hose and Wire Replacement
                c. Hose/Wire Track Replacement
                d. Tube Assembly Wear Pad Replacement
                e. Track Housing Assembly Wear Pad Replacement
                a. Fork Side Shift Hose Carrier Assembly Installation
            3.3.2 Inner Boom Replacement
                a. Inner Boom Removal
                b. Inner Boom Installation
            3.3.3 Attachment Tilt and Fork Side Shift Hydraulics Hose Indexing Procedure
            3.3.4 Intermediate Boom Replacement
                a. Intermediate Boom Removal
                b. Intermediate Boom Installation
            3.3.5 Outer Boom Replacement
                c. Outer Boom Removal
                d. Outer Boom Installation
        3.4 Boom Chains
            3.4.1 Boom Chain Inspection
                a. Inspection Guidelines
                b. Expose Extend Chain for Inspection
                c. Expose Retract Chain for Inspection
            3.4.2 Chain Lubrication
            3.4.3 Boom Chain Tension Check
            3.4.4 Extend Chain Adjustment
            3.4.5 Chain Replacement
        3.5 Boom Wear Pads
            3.5.1 Boom Wear Pad Check
            3.5.2 Boom Wear Pad Replacement
            3.5.3 Boom Wear Pad Lubrication
            3.5.4 Boom Lubrication Points
            3.5.5 Carriage Fork Shafts and Wear Bar Lubrication
            3.5.6 Emergency Boom Lowering and Retracting
                a. Engine or Hydraulic Pump Failure
                b. Hydraulic Line Failure
        3.6 Quick Attach Assembly
            3.6.1 Disconnecting from a Carriage
            3.6.2 Connecting to a Carriage
            3.6.3 Quick Attach Removal
            3.6.4 Quick Attach Installation
        3.7 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator’s Cab and Covers Component Terminology
        4.2 Operator’s Cab
            4.2.1 Operator’s Cab Description
            4.2.2 Serial Number Decal
        4.3 Cab Components
            4.3.1 Seat and Seat Belt Replacement
                a. Seat Removal
                b. Seat Installation
            4.3.2 Steering Wheel, Transmission Travel and Gear Select Lever and Light Switch Control Lever Replacement
                a. Steering Wheel Removal
                b. Steering Wheel Installation
                c. Transmission Travel and Gear Select Lever Removal
                d. Transmission Travel and Gear Select Lever Installation
                e. Light Switch Control Lever Removal
                f. Light Switch Control Lever Installation
            4.3.3 Steering Column and Steering Orbital Replacement
                a. Steering Column and Steering Orbital Removal
                b. Steering Column and Steering Orbital Installation
            4.3.4 Steer Select Valve Replacement
                a. Steer Select Valve Removal
                b. Steer Select Valve Reassembly
                c. Three-Mode Steering Test
                d. Steer Select Valve Installation
            4.3.5 Service Brake Valve and Service Brake Pedal Replacement
                a. Service Brake Valve Removal
                b. Service Brake Valve Installation
                c. Service Brake Pedal Removal
                d. Service Brake Pedal Installation
            4.3.6 Throttle Pedal Replacement
                a. Throttle Pedal Removal
                b. Throttle Pedal Installation
            4.3.7 Throttle Position Sensor Replacement
                a. Throttle Position Sensor Removal
                b. Installation
            4.3.8 Throttle Pedal Adjustment
            4.3.9 Joystick Assembly Replacement
                a. Joystick Assembly Removal
                b. Joystick Assembly Installation
            4.3.10 Miscellaneous Cab Components
            4.3.11 Cab Enclosure Components
        4.4 Enclosed Cab Components
            4.4.1 Heater/Defroster System Replacement
                a. Heater Assembly Removal
                b. Heater Assembly Installation
        4.5 Cab Removal
        4.6 Cab Installation
        4.7 Air Reservoir
            4.7.1 Air Reservoir Replacement
                a. Air Reservoir Removal
                b. Air Reservoir Installation
        4.8 Covers and Guards
            4.8.1 Cover and Guards Replacement
            4.8.2 Engine Hood Replacement
                a. Engine Hood Removal
                b. Engine Hood Installation
                c. Engine Hood Latch Adjustment
                
    Section 5 Axles, Wheels and Tires
        5.1 Axle and Wheel Component Terminology
        5.2 Axle Assemblies
            5.2.1 Axle Assembly Description
            5.2.2 Axle Assembly Operation
            5.2.3 Axle Serial Number Plate
            5.2.4 Axle Specifications
            5.2.5 Axle Maintenance
            5.2.6 Axle Replacement
                a. Removal
                b. Axle Inspection, Internal Service and Repair
                c. Installation
            5.2.7 Axle Service and Troubleshooting
            5.2.8 Axle Assembly Troubleshooting
            5.2.9 Axle Internal Component Troubleshooting
        5.3 Wheels and Tires
            5.3.1 Removing Wheel and Tire Assembly from Vehicle
            5.3.2 Wheel Cleaning
            5.3.3 Wheel Inspection and Replacement
            5.3.4 Installing Wheel and Tire Assembly onto Vehicle
            5.3.5 Tires
                a. Dismounting Tire from Wheel
                b. Wheel Inspection and Replacement
                c. Tire and Wheel Lubrication
                d. Mounting Tire onto Wheel
                e. Tire Speed and Road Surface Limitations
                f. Care and Storage of Tires
                
    Section 6 Transfer Case and Drive Shafts
        6.1 Transfer Case and Drive Shaft Component Terminology
        6.2 General Information
        6.3 Transfer Case
            6.3.1 Transfer Case Description
                a. ZF Transfer Case
                b. Carraro Transfer Case
            6.3.2 Transfer Case Operation
                a. ZF Transfer Case
                b. Carraro Transfer Case
            6.3.3 Serial Number Plate
                a. ZF Transfer Case
                b. Carraro Transfer Case
            6.3.4 Transfer Case Specifications
            6.3.5 Further Information
                a. ZF Transfer Case
                b. Carraro Transfer Case
            6.3.6 Technical Data
                a. ZF Transfer Case
                b. Carraro Transfer Case
            6.3.7 Transfer Case Inspection and Service
            6.3.8 Transfer Case Maintenance
            6.3.9 Transfer Case Removal
                a. ZF Transfer Case
                b. Carraro Transfer Case
            6.3.10 Internal Transfer Case Repair
            6.3.11 Transfer Case Installation
                a. ZF Transfer Case
                b. Carraro Transfer Case
        6.4 Drive Shafts
            6.4.1 Drive Shaft Inspection and Service
            6.4.2 Drive Shaft Maintenance
            6.4.3 Drive Shaft Removal
                a. ZF Transfer Case
                b. Carraro Transfer Case
            6.4.4 Drive Shaft Disassembly
                a. Transfer Case-to-Axle Drive Shafts
                b. Transmission-to-Transfer Case Drive Shaft
            6.4.5 Drive Shaft Cleaning and Drying
            6.4.6 Drive Shaft Assembly
            6.4.7 Drive Shaft Installation
                a. ZF Transfer Case
                b. Carraro Transfer Case
            6.4.8 Slip Yokes
                a. Slip Yoke Inspection
                b. Slip Yoke Removal and Replacement
                c. Slip Yoke Installation
        6.5 Troubleshooting
            6.5.1 Transfer Case and Drive Shaft Troubleshooting
            6.5.2 Transfer Case Internal Component Troubleshooting
            
    Section 7 Transmission: ZF 4 WG-98 TS
        7.1 Transmission Assembly Component Terminology
        7.2 Transmission Description
        7.3 Transmission Operation
        7.4 Transmission Serial Number
        7.5 Transmission Specifications
            7.5.1 Transmission General Specifications
            7.5.2 Transmission Performance Specifications
            7.5.3 Transmission Lubrication
                a. Transmission Fluid
                b. Transmission Fluid (Oil) Capacity
            7.5.4 Transmission-Related Fuse Ratings
        7.6 Transmission Maintenance
            7.6.1 Maintenance Introduction
            7.6.2 Transmission Maintenance Schedule
        7.7 Transmission Replacement
            7.7.1 Transmission Removal
            7.7.2 Transmission Inspection and Internal Repair
            7.7.3 Transmission Installation
            7.7.4 After Transmission Service or Replacement
        7.8 Towing a Disabled Vehicle
        7.9 Troubleshooting
            7.9.1 Transmission Troubleshooting
            
    Section 8 Engine: Cummins QSB4.5T
        8.1 Introduction
            8.1.1 Disclaimer and Scope
            8.1.2 Component Terminology
        8.2 Safety Information
        8.3 Engine Serial Number
        8.4 Specifications and Maintenance Information
        8.5 Standard Practices
            8.5.1 Left and Right Sides of the Engine
            8.5.2 Cleanliness
            8.5.3 Gaskets and O-rings
            8.5.4 Capscrews and Metric Parts
        8.6 Engine Cooling System
            8.6.1 Radiator Pressure Cap
            8.6.2 Thermostat Replacement
                a. Thermostat Removal
                b. Thermostat Installation
            8.6.3 Drain and Flush Radiator
            8.6.4 Radiator/Cooler and Engine Block Heater Replacement
                a. Radiator/Cooler Removal
                b. Radiator/Cooler Installation
                c. Engine Block Heater Removal
                d. Engine Block Heater Installation
        8.7 Engine Electrical System
        8.8 Fuel System
            8.8.1 Diesel Fuel
            8.8.2 Fuel Tank
                a. Removal
                b. Disassembly
            8.8.3 Cleaning and Drying
                c. Inspection
                d. Assembly and Replacement
            8.8.4 Fuel Level Sender and Gauge
            8.8.5 Fuel Lift Pump Testing
                a. Fuel Lift Pump Removal
                b. Cleaning and Drying
                c. Fuel Lift Pump Installation
            8.8.6 Fuel Filter Replacement
            8.8.7 Bleeding Air From The Fuel System
            8.8.8 Fuel Injectors
                a. Locating Faulty Fuel Injectors
                b. Injector Replacement
            8.8.9 After Fuel System Service
        8.9 Engine Exhaust System
            8.9.1 Exhaust System Removal
            8.9.2 Exhaust System Installation
        8.10 Engine Replacement
            8.10.1 Engine Removal
            8.10.2 Engine Disassembly, Inspection and Service
            8.10.3 Engine Installation
        8.11 Engine Storage
        8.12 Troubleshooting
        
    Section 9 Hydraulic System
        9.1 Hydraulic Component Terminology
        9.2 Safety Information
        9.3 Specifications
        9.4 Hydraulic Fluid
        9.5 Hoses, Tube Lines, Fittings, Etc.
            9.5.1 Replacement Considerations
            9.5.2 Hose, Tube, Line and Fitting Replacement
        9.6 Hydraulic Pressure Diagnosis
            9.6.1 Pressure Checks and Adjustments
        9.7 Hydraulic System Testing
            9.7.1 Hydraulic Testing
        9.8 Hydraulic Circuits and Troubleshooting
            9.8.1 Pump, Unloader Valve and Cooling Circuit and Troubleshooting
            9.8.2 Joystick Circuit and Troubleshooting
            9.8.3 Park Brake Circuit and Troubleshooting
            9.8.4 Service Brake Circuit and Troubleshooting
            9.8.5 Emergency Towing Park Brake Release Circuit and Troubleshooting
            9.8.6 Boom Extend Circuit and Troubleshooting
            9.8.7 Boom Retract Circuit and Troubleshooting
            9.8.8 Boom Lift Circuit and Troubleshooting
            9.8.9 Boom Lower Circuit and Troubleshooting
            9.8.10 Frame Sway (Left) and Stabilizer Circuit and Troubleshooting
            9.8.11 Frame Sway (Right) and Stabilizer Circuit and Troubleshooting
            9.8.12 Attachment Tilt (Down) and Slave Cylinder Circuit and Troubleshooting
            9.8.13 Attachment Tilt (Up) and Slave Cylinder Circuit and Troubleshooting
            9.8.14 Front-Wheel Steering Circuit (Left Turn) and Troubleshooting
            9.8.15 Front-Wheel Steering Circuit (Right Turn) and Troubleshooting
            9.8.16 Four-Wheel Steering Circuit (Left Turn) and Troubleshooting
            9.8.17 Four-Wheel Steering Circuit (Right Turn) and Troubleshooting
            9.8.18 Crab Steering Circuit (Left) and Troubleshooting
            9.8.19 Crab Steering Circuit (Right) and Troubleshooting
            9.8.20 Left Fork Shift Circuit (Shift Right) and Troubleshooting
            9.8.21 Left Fork Shift Circuit (Shift Left) and Troubleshooting
            9.8.22 Right Fork Shift Circuit (Shift Right) and Troubleshooting
            9.8.23 Right Fork Shift Circuit (Shift Left) and Troubleshooting
            9.8.24 Pump, Unloader Valve and Cooling Circuit Description
            9.8.25 Joystick Circuit Description
            9.8.26 Brake Circuit Description
                a. Park Brake Circuit (See page 9.20)
                b. Service Brake Circuit (See page 9.22)
                c. Emergency Towing Park Brake Release Circuit (See page 9.24)
            9.8.27 Boom Extend/Retract Circuit Description
            9.8.28 Boom Lift/Lower Circuit Description
            9.8.29 Frame Sway Circuit Description
            9.8.30 Attachment Tilt and Slave Circuit Description
                a. Mode 2A
                b. Mode 2B
            9.8.31 Three-Mode Steering Circuit Descriptions
                a. Front-Wheel Steering
                b. Four-Wheel Steering
                c. Crab Steering Mode
            9.8.32 Fork Side Shift Circuit Description
                a. Left Fork - Shift Right (page 9.54)
                b. Left Fork - Shift Left (page 9.56)
                c. Right Fork - Shift Right (page 9.58)
                d. Right Fork - Shift Left (page 9.60)
        9.9 Steer Indexing Procedures
            9.9.1 Four-Wheel Steer Indexing Procedure
        9.10 Hydraulic Reservoir
            9.10.1 Hydraulic Reservoir Replacement
        9.11 Hydraulic System Pump
            9.11.1 Pump Failure Analysis
            9.11.2 Pump Replacement
                a. Pump Removal
                b. Tools Required for Pump Repair
                c. General Repair Precautions
                d. Pump Disassembly
                e. Pump Cleaning
                f. Pump Inspection
                g. Pump Assembly
                h. Pump Installation
                i. Pump Test
        9.12 Valves and Manifolds
            9.12.1 Unloader Valve
                a. Unloader Valve Removal
                b. Unloader Valve Disassembly, Inspection and Assembly
                c. Unloader Valve Installation
                d. Unloader Valve Pressure Check Test
            9.12.2 Valve Plate Assembly
                a. Valve Plate Removal
            9.12.3 Main Control Valve
                a. Main Control Valve Removal from Valve Plate
                b. Main Control Valve Disassembly
                c. Main Control Valve Disassembly
                d. Main Control Valve Parts Cleaning
                e. Main Control Valve Parts Inspection
                f. Main Control Valve Assembly
                g. Main Control Valve Assembly
                h. Main Control Valve Installation
                i. Main Control Valve Test
            9.12.4 Pilot Select Manifold
                a. Pilot Select Manifold Removal
                b. Pilot Select Manifold Disassembly, Cleaning, Inspection and Assembly
                c. Pilot Select Manifold Installation
                d. Pilot Select Manifold Test
            9.12.5 Secondary Function Manifold
                a. Secondary Function Manifold Replacement
                b. Secondary Function Manifold Disassembly, Cleaning, Inspection and Assembly
                c. Secondary Function Manifold Installation
                d. Secondary Function Manifold Test
            9.12.6 Joystick Valve
            9.12.7 Service Brake Valve
                a. Service Brake Valve Removal
                b. Service Brake Valve Reassembly
                c. Service Brake Valve Installation
                d. Brake Test
            9.12.8 Power Steering Valve
                a. Power Steering Valve Removal
                b. Power Steering Valve Reassembly
                c. Power Steering Valve Installation
                d. Power Steering Test
            9.12.9 Steer Select Valve (Three-Mode Steer)
                a. Steer Select Manifold and Valve Removal
                b. Steer Select Valve Reassembly
                c. Steer Select Valve Installation
                d. Steering Test
            9.12.10 Accumulator Charge Valve
                a. Accumulator Charge Valve Replacement
                b. Accumulator Charge Valve Disassembly, Cleaning, Inspection and Assembly
                c. Accumulator Charge Valve Installation
                d. Accumulator Charge Valve Test
            9.12.11 Fork Side Shift Valve
                a. Fork Side Shift Manifold and Valve Removal
                b. Fork Side Shift Valve and Manifold Disassembly, Cleaning, Inspection and Assembly
                c. Fork Side Shift Manifold And Valve Installation
                d. Fork Side Shift Valve Test
        9.13 Accumulators
            9.13.1 General Information
            9.13.2 Pre-Charging Accumulator
            9.13.3 Checking Pre-Charge
            9.13.4 Accumulator Charge Troubleshooting
        9.14 Hydraulic Cylinders
            9.14.1 General Cylinder Disassembly Instructions
            9.14.2 General Cylinder Cleaning Instructions
            9.14.3 General Cylinder Assembly Instructions
            9.14.4 Attachment Tilt Cylinder
                a. Attachment Tilt Cylinder Removal
                b. Attachment Tilt Cylinder Disassembly
                c. Attachment Tilt Cylinder Cleaning
                d. Attachment Tilt Cylinder Inspection
                e. Attachment Tilt Cylinder Assembly
                f. Attachment Tilt Cylinder Installation
                g. Attachment Tilt Cylinder Pressure Checking and Circuit Bleeding
            9.14.5 Slave Cylinders
                a. Slave Cylinder Removal
                b. Slave Cylinder Disassembly
                c. Slave Cylinder Cleaning
                d. Slave Cylinder Inspection
                e. Slave Cylinder Assembly
                f. Slave Cylinder Installation
                g. Slave Cylinder Pressure Checking and Circuit Bleeding
            9.14.6 Extend/Retract Cylinder
                a. Extend/Retract Cylinder Removal
                b. Extend/Retract Cylinder Disassembly
                c. Extend/Retract Cylinder Cleaning
                d. Extend/Retract Cylinder Inspection
                e. Extend/Retract Cylinder Assembly
                f. Extend/Retract Cylinder Installation
                g. Extend/Retract Cylinder Pressure Checking and Circuit Bleeding
            9.14.7 Lift/Lower Cylinder
                a. Lift/Lower Cylinder Removal
                b. Lift/Lower Cylinder Disassembly
                c. Lift/Lower Cylinder Cleaning
                d. Lift/Lower Cylinder Inspection
                e. Lift/Lower Cylinder Assembly
                f. Lift/Lower Cylinder Installation
                g. Lift/Lower Cylinder Pressure Checking and Circuit Bleeding
            9.14.8 Frame Sway Cylinder
                a. Frame Sway Cylinder Removal
                b. Frame Sway Cylinder Disassembly
                c. Frame Sway Cylinder Internal Cleaning
                d. Frame Sway Cylinder Inspection and Repair
                e. Frame Sway Cylinder Assembly
                f. Frame Sway Cylinder Installation
                g. Frame Sway Cylinder Pressure Checking and Circuit Bleeding
            9.14.9 Stabilizer Cylinder
                a. Stabilizer Cylinder Removal
                b. Stabilizer Cylinder Disassembly
                c. Stabilizer Cylinder Internal Cleaning
                d. Stabilizer Cylinder Inspection and Repair
                e. Stabilizer Cylinder Assembly
                f. Stabilizer Cylinder Installation
                g. Stabilizer Cylinder Pressure Checking and Circuit Bleeding
            9.14.10 Steering Cylinders
            9.14.11 Side Shift Cylinders (7K Carriage)
                a. Side Shift Cylinder Removal
                b. Fork Side Shift Cylinder Disassembly
                c. Fork Side Shift Cylinder Internal Cleaning
                d. Fork Side Shift Cylinder Inspection and Repair
                e. Fork Side Shift Cylinder Assembly
                f. Fork Side Shift Cylinder Installation
            9.14.12 Side Shift Cylinders (11K Carriage)
                a. Side shift Cylinder Removal
                b. Fork side Shift Cylinder Disassembly
                c. Fork Side Shift Cylinder Internal Cleaning
                d. Fork Side Shift Cylinder Inspection and Repair
                e. Fork Side Shift Cylinder Assembly
                f. Fork Side Shift Cylinder Installation
                
    Section 10 Electrical System
        10.1 Electrical Component Terminology
            10.1.1 General Overview (Cab Harness)
            10.1.2 General Overview (Vehicle Harness)
            10.1.3 General Overview (Battery, Equalizer Harness)
            10.1.4 General Overview (Lighting Harness)
            10.1.5 General Overview (A/C, Heater, Wiper Harness)
            10.1.6 General Overview (Vehicle Ground Strap Locations)
        10.2 Service Warnings
            10.2.1 General
            10.2.2 Battery
        10.3 Specifications
        10.4 Effective Ground Connections
        10.5 Wiring Harnesses
            10.5.1 Removal and Replacement
            10.5.2 Disassembly
            10.5.3 Cleaning and Drying
            10.5.4 Inspection and Repair
            10.5.5 Installation
            10.5.6 Wire Code and Color
        10.6 Fuses and Relays
            10.6.1 Circuit Protection - Fuses
                a. Auto Type Fuses
                b. Battery Equalizer Fuses
            10.6.2 Fuse and Relay Locations
                a. Fuse Block Relay Locations
                b. Fuse Block Fuse Locations
                c. Fuses, Relays and Flasher (Right Side Console)
                d. Engine Compartment Fuses
                e. Relay and Fuse (Inside Rear Door)
                f. Engine Compartment Relay Locations
            10.6.3 Fuse and Relay Replacement
                a. Fuse Removal
                b. Relay Removal
        10.7 Electrical System Troubleshooting
            10.7.1 Introduction
            10.7.2 ECM Diagnostic System
                a. Fault Detection
                b. Flash-Out of Fault Codes
            10.7.3 Troubleshooting with a Digital Multimeter (DMM)
            10.7.4 Probing Electrical Connectors
                a. Front Probe
                b. Back Probe
                c. Measuring Voltage
            10.7.5 Electrical Schematic Legend
            10.7.6 Electrical Symbols Directory
            10.7.7 Main Electrical Schematic (Sheet 1 of 3)
            10.7.8 Main Electrical Schematic (Sheet 2 of 3)
            10.7.9 Main Electrical Schematic (Sheet 3 of 3)
            10.7.10 Engine Start Circuit and Troubleshooting
            10.7.11 Electronic Throttle Circuit and Troubleshooting
            10.7.12 Charging Circuit and Troubleshooting
            10.7.13 Frame Sway Circuit and Troubleshooting
            10.7.14 Boom Extend/Retract Circuit and Troubleshooting
            10.7.15 Boom Lift/Lower Circuit and Troubleshooting
            10.7.16 Attachment Tilt, Mode 2A, Circuit and Troubleshooting
            10.7.17 Attachment Tilt, Mode 2B, Circuit and Troubleshooting
            10.7.18 Left Fork - Side Shift LEFT, Circuit and Troubleshooting
            10.7.19 Left Fork - Side Shift RIGHT, Circuit and Troubleshooting
            10.7.20 Right Fork - Side Shift LEFT, Circuit and Troubleshooting
            10.7.21 Right Fork - Side Shift RIGHT, Circuit and Troubleshooting
            10.7.22 Load Moment Indicator Circuit and Troubleshooting
            10.7.23 Cab Main Power Circuit and Troubleshooting
            10.7.24 Cab Heater & Air Conditioning Blower Motor Circuit and Troubleshooting
            10.7.25 Air Conditioning Circuit and Troubleshooting
            10.7.26 Front Wiper/Washer Circuit and Troubleshooting
            10.7.27 Skylight Wiper/Washer, Rear Washer Circuit and Troubleshooting
            10.7.28 Rear Wiper Circuit and Troubleshooting
        10.8 Transmission Gear Selection Troubleshooting
            10.8.1 Transmission, Forward - First Gear Circuit
            10.8.2 Transmission, Forward - Second Gear Circuit
            10.8.3 Transmission, Forward - Third Gear Circuit
            10.8.4 Transmission, Forward - Fourth Gear Circuit
            10.8.5 Transmission, Reverse - First Gear Circuit
            10.8.6 Transmission, Reverse - Second Gear Circuit
            10.8.7 Transmission, Reverse - Third Gear Circuit
        10.9 Dash Panel Warning Indicator Troubleshooting
            10.9.1 Engine Alternator Charging Warning Indicator Troubleshooting
            10.9.2 Engine Coolant Temperature Gauge Troubleshooting
            10.9.3 Engine Oil Pressure Warning Indicator Troubleshooting
            10.9.4 Engine Air Filter Restriction Warning Indicator Troubleshooting
            10.9.5 Engine Tachometer & Hourmeter Indicator Troubleshooting
            10.9.6 Transmission Temperature Warning Indicator Troubleshooting
            10.9.7 Dual Hydraulic Oil Temperature Warning Indicator Troubleshooting
            10.9.8 Hydraulic Oil Filter Restriction Warning Indicator Troubleshooting
            10.9.9 Park Brake Warning Indicator Troubleshooting
            10.9.10 Low Brake Pressure Indicator Troubleshooting
            10.9.11 Fuel Level Gauge Troubleshooting
            10.9.12 Stabil-TRAK™ “Locked” Mode Indicator Troubleshooting
            10.9.13 Stabil-TRAK™ “Slow Pivot” Mode Indicator Troubleshooting
            10.9.14 Engine Air-Intake Heater Indicator Troubleshooting
        10.10 Engine Start Circuit
            10.10.1 Starting Circuit
            10.10.2 Starter
                a. Testing the Starter on the Engine
                b. Starter Circuit Checks
                c. Starter Removal
                d. Starter Cleaning and Drying
                e. Starter Periodic Maintenance
                f. Starter Installation
        10.11 Charging Circuit
            10.11.1 Alternator
                a. Alternator Removal
                b. Alternator Installation
            10.11.2 Batteries
                a. Battery Description
                b. Visual Inspection of the Battery
                c. Battery Load Test
                d. Battery Charging
                e. Battery Troubleshooting
                f. Slave Starting with a Booster Vehicle
                g. Battery Removal
                h. Battery Inspection, Cleaning and Drying
                i. Battery Installation
            10.11.3 Battery Equalizer
                a. Battery Equalizer System Description
                b. Battery Equalizer Maintenance
                c. Battery Equalizer Testing
                d. Battery Equalizer Removal
                e. Battery Equalizer Install
            10.11.4 Battery Solargizer®
                a. Battery Solargizer® System Description
                b. Solargizer® Testing
                c. Solargizer® Control Box Removal
                d. Solargizer® Control Box Installation
                e. Solar Panel Removal
                f. Solar Panel Installation
        10.12 Electrical System Components
            10.12.1 Warning Devices
                a. Horn
            10.12.2 Warning Indicator Lights
                a. Transmission Temperature Warning Indicator
                b. Hydraulic Oil Temperature Warning Indicator
                c. Hydraulic Oil Filter Restriction Warning Indicator
                d. Engine Air Filter Restriction Warning Indicator
                e. Alternator Charging Warning Indicator
                f. Engine Oil Pressure Warning Indicator
                g. Low Brake Pressure Warning Indicator
            10.12.3 Engine Function Indicator Lights
            10.12.4 Back-Up Alarm
                a. Back-Up Alarm Removal
                b. Disassembly
                c. Inspection and Replacement
                d. Installation and Testing
            10.12.5 Front Dash Panel
                a. Power-Up Lights
                b. Function Indicator Lights
                c. Gauges and Indicators
                d. Front Dash Panel Bulb Replacement
            10.12.6 Throttle Position Sensor
                a. Inspection and Replacement
                b. Removal
                c. Disassembly
                d. Cleaning and Drying
                e. Installation and Testing
            10.12.7 Front Windshield Wiper Switch
                a. Removal
                b. Disassembly
                c. Cleaning and Drying
                d. Inspection and Replacement
                e. Installation and Testing
            10.12.8 Front Windshield Wiper Motor
                a. Removal
                b. Disassembly
                c. Cleaning and Drying
                d. Inspection and Replacement
                e. Installation and Testing
            10.12.9 Windshield Washer Switch
                a. Removal
                b. Disassembly
                c. Cleaning and Drying
                d. Inspection and Replacement
                e. Installation and Testing
            10.12.10 Skylight Wiper/Washer & Rear Window Washer Switch
                a. Removal
                b. Disassembly
                c. Cleaning and Drying
                d. Inspection and Replacement
                e. Installation and Testing
            10.12.11 Skylight Wiper Motor
                a. Removal
                b. Disassembly
                c. Cleaning and Drying
                d. Inspection and Replacement
                e. Installation and Testing
            10.12.12 Windshield/Skylight/Rear Window Washer Reservoir w/Pump
                a. Removal
                b. Disassembly
                c. Cleaning and Drying
                d. Inspection and Replacement
                e. Installation and Testing
            10.12.13 Rear Wiper Switch/Motor
                a. Removal
                b. Disassembly
                c. Cleaning and Drying
                d. Inspection and Replacement
                e. Installation and Testing
            10.12.14 Cab Heater/Air Conditioning Controls
                a. To heat the cab:
                b. To defrost the cab:
                c. To cool the cab:
                a. Cab Heater Controls Removal
                b. Disassembly
                c. Cleaning and Drying
                d. Inspection and Replacement
                e. Installation and Testing
            10.12.15 Fork Side Shift Switches
                a. Removal
                b. Disassembly
                c. Cleaning and Drying
                d. Inspection and Replacement
                e. Installation and Testing
            10.12.16 Cab Circulation Fan Switch
                a. Fan Switch Test
                b. Removal
                c. Installation and Testing
            10.12.17 Load Moment Indicator (LMI)
                a. LMI Description
                b. Calibration
                c. Fault Conditions
        10.13 Switches and Solenoids
            10.13.1 Ignition Switch
                a. Ignition Switch Removal
                b. Disassembly
                c. Inspection and Replacement
                d. Ignition Switch Installation
                e. Transmission Neutral Start Feature
            10.13.2 Hydraulic Oil Filter Pressure Switch
                a. Hydraulic Oil Filter Pressure Switch Removal
                b. Disassembly
                c. Cleaning and Drying
                d. Inspection and Replacement
                e. Installation and Testing
            10.13.3 Hydraulic Oil Temperature Switch
                a. Hydraulic Oil Temperature Switch Removal
                b. Hydraulic Oil Temperature Switch Disassembly
                c. Hydraulic Oil Temperature Switch Cleaning and Drying
                d. Hydraulic Oil Temperature Switch Inspection and Replacement
                e. Installation and Testing
            10.13.4 Parking Brake Switch
                a. Parking Brake Switch Removal
                b. Parking Brake Switch Disassembly
                c. Parking Brake Switch Inspection and Replacement
                d. Parking Brake Switch Installation and Testing
            10.13.5 Transmission Disconnect Switch
                a. Transmission Disconnect Switch Removal
                b. Transmission Disconnect Switch Disassembly
                c. Transmission Disconnect Switch Inspection and Replacement
                d. Transmission Disconnect Switch Installation and Testing
            10.13.6 Stabilizer Brake Switch
                a. Stabilizer Brake Switch Removal
                b. Stabilizer Brake Switch Installation
                c. Stabilizer Brake Switch Adjustment
            10.13.7 Brake Light Switch
            10.13.8 Transmission Shift Control Switch
                a. Travel Select Lever (10)
                b. Gear Select Lever
            10.13.9 Transmission Solenoid Valves
                a. Travel Select Lever and Wiring Harness Testing
                b. Upper and Lower Transmission Valve Body Solenoid Testing
                c. Transmission Upper Valve Body Solenoid Removal
                d. Transmission Upper Valve Body Solenoid Installation
                e. Transmission Lower Valve Body Solenoid Removal
                f. Transmission Lower Solenoid Valve Inspection
                g. Transmission Lower Solenoid Valve Installation
            10.13.10 Attachment Tilt Mode Switch
                a. Attachment Tilt Mode Switch Removal
                b. Attachment Tilt Mode Switch Disassembly
                c. Attachment Tilt Mode Switch Inspection and Replacement
                d. Attachment Tilt Mode Switch Installation
            10.13.11 Joystick
                a. Joystick Button Testing
                b. Joystick Function Solenoid Valves
                c. Solenoid Coil and Cartridge Valve Replacement
                d. Joystick Handle Replacement
            10.13.12 Logic Board Panel
                a. Boom Sensor (Proximity Switch)
                b. Boom Sensor Replacement and Adjustment
            10.13.13 Engine Coolant High Temperature Sender
                a. Engine Coolant Temperature Sender Removal
                b. Engine Coolant Temperature Sender Disassembly
                c. Engine Coolant Temperature Sender Inspection and Replacement
                d. Engine Coolant Temperature Sender Installation and Testing
            10.13.14 Transmission Temperature Sender
                a. Transmission Temperature Switch Removal
                b. Transmission Temperature Switch Disassembly
                c. Transmission Temperature Switch Inspection and Replacement
                d. Transmission Temperature Switch Installation and Testing
            10.13.15 Fuel Level Gauge and Sender
                a. Fuel Level Gauge Testing
                b. Fuel Level Circuit Tests
            10.13.16 Hourmeter
            10.13.17 Engine Block Heater
                a. Engine Block Heater Testing
                b. Engine Block Heater Removal
                c. Engine Block Heater Disassembly
                d. Engine Block Heater Inspection and Replacement
                e. Engine Block Heater Installation
                
    Section 11 Stabil-TRAK™ System
        11.1 Stabil-TRAK™ System Component Terminology
        11.2 Stabil-TRAK™ Description
        11.3 Stabil-TRAK™ Operation
            11.3.1 Understanding the Stabil-TRAK™ System
                a. Free Pivot Mode (6)
                b. Locked Mode (8)
                c. Slow Pivot Mode (11)
            11.3.2 Stabil-TRAK™ Solenoid Valves
        11.4 Stabil-TRAK™ Electrical Circuit Operation And Troubleshooting
            11.4.1 Electrical Troubleshooting Charts
            11.4.2 Stabil-TRAK™ Electrical Circuit - Not in FREE PIVOT Mode when Boom below 40˚
            11.4.3 Stabil-TRAK™ Electrical Circuit - Not in SLOW PIVOT Mode when Boom above 40˚
            11.4.4 Stabil-TRAK™ Electrical Circuit - Not in LOCKED Mode when Boom above 40˚
        11.5 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting
            11.5.1 Troubleshooting Symptom Chart
            11.5.2 Stabilizer Cylinder Oil Flow
            11.5.3 Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil Out
            11.5.4 Hydraulic Troubleshooting - FREE PIVOT Mode, Rod Oil Out
            11.5.5 Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil Out
            11.5.6 Hydraulic Troubleshooting - FREE PIVOT Mode, Base Oil Out
            11.5.7 Hydraulic Circuit Operation - SLOW PIVOT Mode, Rod Oil Out
            11.5.8 Hydraulic Troubleshooting - SLOW PIVOT Mode, Rod Oil Out
            11.5.9 Hydraulic Circuit Operation - SLOW PIVOT Mode, Base Oil Out
            11.5.10 Hydraulic Troubleshooting - SLOW PIVOT Mode, Base Oil Out
            11.5.11 Hydraulic Circuit Operation - LOCKED Mode
                a. Conditions:
                b. Operation:
            11.5.12 Hydraulic Circuit Operation - LOCKED Mode, Frame Sway Right
            11.5.13 Hydraulic Circuit Operation - LOCKED Mode, Frame Sway Left
                a. Conditions
                b. Operation
        11.6 Stabil-TRAK™ System Test
            11.6.1 Stabil-TRAK™ System Test Instructions
            11.6.2 Stabil-TRAK™ System Test Procedures
            
    Section 12 Index
        A
        Access Panels and Covers
            Engine Hood 4.34
            Replacement 4.1, 4.33
        Accident Prevention Tag Usage 1.4
        Accumulator Charge Valve 9.110
        After Service Startup and Checks
            Axle Service 2.31
            Boom Service 2.31
            Brake System Service 2.30
            Electrical/Electronic Component Service 2.30
            Engine Service 2.31
            Fuel System Service 2.31
            Hydraulic Component Service 2.30
            Tire and Wheel Service 2.31
            Transmission Service or Replacement 2.31
        Air Cleaner
            Maintenance Instructions 2.35
        Air Conditioner Compressor Belt 2.44
        Air Conditioning Controls 10.162
        Air Transport, C-130 Configuration 2.81
        Air Transport, C-17, C141 or C-5 Tiedowns 2.80
        Alternate Fuel Types 8.19
        Alternator 10.117
        Attachment Tilt Mode Switch 10.189
        Axle Assemblies
            Description 5.3
            Internal Component Troubleshooting 5.15
            Maintenance 5.4
            Operation 5.3
            Replacement 5.5
            Serial Number Plate 5.3
            Service 5.12
            Specifications 5.4
            Troubleshooting 5.12
        Axle Oil
            Maintenance Instructions 2.49
        Axles, Wheels and Tires
            Axle and Wheel Component Terminology 5.2
            Axle Assemblies 5.3
            Wheels and Tires 5.16
                B
        Back-Up Alarm 10.136
        Batteries 10.120
        Battery
            Electrolyte First Aid 2.59, 7.17
            Equalizer 10.124
            Equalizer Fuses 10.16
            Maintenance Instructions 2.58
            Solargizer® 10.132
        Bearings
            Cleaning 2.29
            Installation 2.29
            Removal 2.29
        Bleeding Fuel System 2.43, 8.23
        Boom
            Assembly Maintenance 3.3
            Description 3.3
            Operation 3.3
            Quick Attach Assembly 3.48
            System 3.3
            System Component Terminology 3.2
            Troubleshooting 3.50
        Boom Assembly Maintenance
            Attachment Tilt and Auxiliary Hydraulics Hose Indexing Procedure 3.17
            Boom Chain Inspection 3.26
            Boom Chains 3.26
            Boom Lubrication Points 3.41
            Boom Wear Pads 3.37
            Emergency Boom Lowering and Retracting 3.42
            Hose Carrier Assembly Replacement 3.4
            Inner Boom Replacement 3.9
            Intermediate Boom Replacement 3.18
            Outer Boom Replacement 3.20
        Boom Chain Inspection
            Chain Lubrication 3.32
            Guidelines 2.67, 3.27
            Maintenance Instructions 2.67
        Boom Chains
            Maintenance Instructions 2.70
        Boom Sensor (Proximity Switch) 10.196
        Boom Wear Pad Maintenance 2.66
        Brake Disc Wear Check
            Maintenance Instructions 2.50
        Brake Light Switch 10.183
            C
        Cab and Covers
            Cab Installation 4.27
            Cab Removal 4.24
            Component Terminology 4.2
            Enclosed Cab Components 4.22
            Open Cab Components 4.4
            Operator’s Cab 4.3
        Cab Circulation Fan Switch 10.166
        Cab Heater Controls 10.162
        Cab Installation 4.27
        Cab Removal 4.24
        Charging Circuit
            Alternator 10.117
            Batteries 10.120
            Battery Equalizer 10.124
            Battery Solargizer® 10.132
        Closed Cab Air Filters
            Maintenance Instructions 2.36
        Cold Start Grid Heater Fuse 10.16, 10.19
        Counterweight Removal and Reassembly
            Maintenance Instructions 2.76
                D
        Dash Panel Troubleshooting
            Dual Hydraulic Oil Temperature Warning Indicator 10.105
            Engine Air Filter Restriction Warning Indicator 10.102
            Engine Air-Intake Heater Indicator 10.112
            Engine Alternator Charging Warning Indicator 10.99
            Engine Coolant Temperature Gauge 10.100
            Engine Oil Pressure Warning Indicator 10.101
            Engine Tachometer & Hourmeter Indicator 10.103
            Fuel Level Gauge 10.109
            Hydraulic Oil Filter Restriction Warning Indicator 10.106
            Low Brake Pressure Indicator 10.108
            Park Brake Warning Indicator 10.107
            Stabil-TRAK "Locked" Mode Indicator 10.110
            Stabil-TRAK "Slow Pivot" Mode Indicator 10.111
            Transmission Temperature Warning Indicator 10.104
        Drive Shafts
            Assembly 6.16
            Cleaning and Drying 6.16
            Disassembly 6.15
            Inspection and Service 6.12
            Installation 6.17
            Maintenance 6.12
            Removal 6.12
            Slip Yokes 6.20
                E
        ECM Diagnostic System 10.20
        ECM Fuses 2.63, 10.16, 10.19
        Electrical Component Terminology
            General Overview
        Electrical System
            Air Conditioning Controls 10.162
            Back-Up Alarm 10.136
            Cab Circulation Fan Switch 10.166
            Cab Heater Controls 10.162
            Charging Circuit 10.116
            Components 10.134
            Dash Panel Warning Indicator Troubleshooting 10.98
            Effective Ground Connections 10.11
            Electrical Troubleshooting 10.20
            Engine Function Indicator Lights 10.136
            Engine Start Circuit 10.113
            Fork Side Shift Switches 10.165
            Front Dash Panel 10.138
            Front Windshield Wiper Motor 10.146
            Front Windshield Wiper Switch 10.145
            Fuses and Relays 10.13
            Load Moment Indicator 10.167
            Rear Window Washer Switch 10.152
            Rear Wiper Switch/Motor 10.158
            Service Warnings 10.10
            Skylight Wiper Motor 10.154
            Skylight Wiper/Washer Switch 10.152
            Specifications 10.11
            Switches and Solenoids 10.170
            Terminology 10.4
            Throttle Position Sensor 10.143
            Transmission Gear Selection Troubleshooting 10.90
            Warning Devices 10.134
            Warning Indicator Lights 10.134
            Windshield Washer Switch 10.150
            Windshield/Skylight/Rear Window Washer Reservoir w/Pump 10.156
            Wiring Harnesses 10.12
        Electrical System Components
            944E-42 Throttle Rotary Position Sensor 4.15
        Electrical System Troubleshooting
            Air Conditioning 10.82
            Attachment Tilt
            Boom Extend/Retract Circuit 10.60
            Boom Lift/Lower Circuit 10.62
            Cab Heater & Air Conditioning Blower Motor 10.80
            Cab Main Power 10.78
            Charging Circuit 10.56
            Electrical Schematic Legend 10.27
            Electrical Symbols Directory 10.41
            Electronic Throttle Circuit 10.54
            Engine Start Circuit 10.48
            Frame Sway Circuit 10.58
            Front Wiper/Washer Circuit 10.84
            Introduction 10.20
            Left Fork Side Shift LEFT Circuit 10.68
            Left Fork Side Shift RIGHT Circuit 10.70
            Load Moment Indicator Circuit 10.76
            Main Electrical Schematic 10.42 - 10.46
            Probing Electrical Connectors 10.22
            Rear Wiper Circuit 10.88
            Right Fork Side Shift LEFT Circuit 10.72
            Right Fork Side Shift RIGHT Circuit 10.74
            Skylight Wiper/Washer, Rear Washer Circuit 10.86
            Troubleshooting with a Digital Multimeter (DMM) 10.21
        Emergency Exit Rear Window 1.6
        Emergency Operations
            Boom Lowering and Retracting 2.86
            Towing a Disabled Vehicle Long Distances 2.84
            Towing a Disabled Vehicle Short Distances 2.83
        Emergency Tire Inflation System
            Maintenance Instructions 2.57
        Enclosed Cab (Optional) Components 4.22
        Enclosed Cab Components
            Heater/Defroster System 4.22
        Engine Block Heater 10.202
        Engine Coolant High Temperature Sender 10.197
        Engine Cooling System
            Maintenance Instructions 2.37
            Radiator Pressure Cap 8.7
            Thermostat Replacement 8.7
        Engine Exhaust System
            Installation 8.27
            Removal 8.26
        Engine Fan Belt
            Maintenance Instructions 2.44
        Engine Fuel System
            Maintenance Instructions 2.42
        Engine Function Indicator Lights 10.136
        Engine Oil and Filter
            Maintenance Instructions 2.39
        Engine Replacement
            Disassembly, Inspection and Service 8.38, 8.39
            Removal 8.28
        Engine Start Circuit
            Starter 10.114
        Engine: Cummins 4BT3.9
            Cooling System 8.7
            Electrical System 8.17
            Exhaust System 8.26
            Fuel System 8.18
            Introduction 8.2
            Replacement 8.28
            Safety Information 8.4
            Serial Number 8.6
            Specifications and Maintenance Information 8.6
            Standard Practices 8.6
            Storage 8.47
            Troubleshooting 8.48
        External Transport/Slinging 2.82
            F
        Flasher 2.62, 10.15
        Fluids, Lubricants and Capacities
            Axles (Differential Housings) 2.22
            Carriage Fork Shafts 2.25, 3.41
            Drive Shaft Splines 2.25
            Engine 2.23
            General Anti-Corrosion 2.25
            Hydraulic System 2.23
            Lubrication Points (Grease Fittings) 2.23
            Paint 2.26
            Thread Locking Compound 2.27
            Transfer Case 2.24
            Transmission 2.24, 2.25
            Wheel Ends 2.22
        Fork Side Shift Valve 9.114
        Four Wheel Steer Indexing Procedure 2.90
        Front Dash Panel 10.138
        Front Windshield Wiper Motor 10.146
        Front Windshield Wiper Switch 10.145
        Fuel Filter Replacement 8.22
        Fuel Injectors 8.24
        Fuel Level Gauge 10.200
        Fuel Level Sender 10.200
        Fuel Lift Pump Testing 8.22
        Fuel System 8.18
            After Fuel System Service 8.25
            Diesel Fuel 8.19
            Fuel Filter 8.22
            Fuel Injectors 8.24
            Fuel Level Sender and Gauge 8.21
            Fuel Lift Pump Testing 8.22
            Fuel Tank 8.19
            Venting Air from the Fuel System 8.23
        Fuses 2.61
        Fuses and Relays
            Circuit Protection - Fuses 10.13
            Locations 10.14
            Maintenance Instructions 2.60
            Replacement 10.18
                G
        General Information, Specifications and Maintenance
            After Service Startup and Checks 2.30
            Bearings 2.29
            Cleaning 2.28
            Component Terminology 2.5
            Emergency Operations 2.83
            Fluids, Lubricants and Capacities 2.22
            Hoses and Tubes 2.28
            Introduction 2.6
            Maintenance Instructions 2.32
            Metric Conversion Factors 2.10
            Parking Brake/Transmission De-Clutch Test Procedures 2.87
            Pressure Testing and Adjustment 2.29
            Replacement 2.28
            Specifications 2.12
            Torques 2.7
        GIC Clearance 2.79
        Ground Strap Locations 10.9
            H
        Hazard/Emergency Information Signs 1.7
        Horn 10.134
        Hoses and Tubes
            Inspection 2.28
            Installation 2.28
        Hoses, Tube Lines, Fittings, Etc.
            Replacement 9.6
            Replacement Considerations 9.6
        Hourmeter 10.202
        Hydraulic Circuits and Troubleshooting
            Attachment Tilt (Down) and Slave Cylinder Circuit 9.38
            Attachment Tilt (Up) and Slave Cylinder Circuit 9.40
            Attachment Tilt and Slave Circuit Description 9.64
            Boom Extend Circuit 9.26
            Boom Extend/Retract Circuit Description 9.63
            Boom Lift Circuit 9.30
            Boom Lift/Lower Circuit Description 9.63
            Boom Lower Circuit 9.32
            Boom Retract Circuit 9.28
            Brake Circuit Description 9.62
            Crab Steering Circuit
            Four-Wheel Steering Circuit
            Frame Sway (Left) and Stabilizer Circuit 9.34
            Frame Sway (Right) and Stabilizer Circuit 9.36
            Frame Sway Circuit Description 9.64
            Front-Wheel Steering Circuit
            Joystick Circuit 9.18
            Joystick Circuit Description 9.62
            Left Fork Shift Circuit
            Pump, Unloader Valve and Cooling Circuit 9.16
            Pump, Unloader Valve and Cooling Circuit Description 9.62
            Right Fork Shift Circuit
            Service Brake Circuit 9.22
            Three-Mode Steering Circuit Descriptions 9.66
        Hydraulic Cylinders
            Attachment Tilt Cylinder 9.125
            Extend/Retract Cylinder 9.134
            Frame Sway Cylinder 9.143
            General Cylinder Assembly Instructions 9.124
            General Cylinder Cleaning Instructions 9.124
            General Cylinder Disassembly Instructions 9.124
            Lift/Lower 9.138
            Slave Cylinders 9.130
            Stabilizer Cylinder 9.148
            Steering Cylinders 9.152
        Hydraulic Oil Filter Pressure Switch 10.173
        Hydraulic Oil Temperature Switch 10.175
        Hydraulic Pressure Diagnosis
            Pressure Checks and Adjustments 9.8
        Hydraulic System
            Cylinders 9.124
            Fluid 9.5
            Hoses, Tube Lines, Fittings, Etc. 9.6
            Hydraulic Circuits and Troubleshooting 9.15
            Hydraulic Component Terminology 9.3
            Pressure Diagnosis 9.7
            Pump Failure Analysis 9.74
            Pump Replacement 9.74
            Reservoir 9.72
            Reservoir Replacement 9.73
            Safety Information 9.4
            Specifications 9.5
            System Pump 9.73
            System Testing 9.10
            Valves and Manifolds 9.84
        Hydraulic System Oil and Filter
            Maintenance Instructions 2.45
        Hydraulic System Testing 9.10
            I
        Ignition Switch 10.170
        Introduction 1.2
            Component Terminology 8.2
            Disclaimer 2.6
            Disclaimer and Scope 8.2
            Replacement Parts and Warranty Information 2.6
            Service Methods 2.6
            The Owners/Operators Manual 2.6
                J
        Joystick 10.191
        Joystick Handle Replacement 10.193
            L
        Load Moment Indicator 10.167
        Logic Board Panel 10.195
        Long Term Storage
            Maintenance Instructions 2.74
                M
        Maintenance Instructions
            Air Cleaner 2.35
            Axle Oil 2.49
            Battery 2.58
            Boom Chain Inspection 2.67
            Boom Chains 2.70
            Boom Wear Pad Maintenance 2.66
            Brake Disc Wear Check 2.50
            Closed Cab Air Filters 2.36
            Counterweight Removal and Reassembly 2.76
            Emergency Tire Inflation System 2.57
            Engine Cooling System 2.37
            Engine Fan Belt 2.44
            Engine Fuel System 2.42
            Engine Oil and Filter 2.39
            Fuse and Relay Replacement 2.60
            Hydraulic System Oil and Filter 2.45
            Long Term Storage 2.74
            Maintenance Schedule and Checklist 2.32
            Short Term Storage 2.74
            Transfer Case Oil 2.54
            Transmission Oil and Filter 2.47
            Transport 2.78
            Wheel End Oil 2.52
            Wheels and Tires 2.56
        Maintenance Schedule and Checklist 2.32
        Marine Transportability 2.82
        Metric Conversion Factors
            American to Metric Conversions 2.10
            Metric to American Conversions 2.10
                O
        Open Cab Components
            Brake Pedal and Valve 4.11
            Miscellaneous Cab Components 4.20
            Seat And Seat Belt 4.4
            Single Joystick Assembly Replacement 4.18
            Steering Column/Valve Replacement 4.6
            Steering Wheel, Column and Shifter 4.4
            Throttle Pedal Replacement 4.14
        Operator’s Cab
            Description 4.3
            Serial Number Decal 4.3
        Owners/Operators Manual 1.2
            P
        Parking Brake Switch 10.176
            Q
        Quick Attach Assembly
            Connecting An Attachment 3.48
            Disconnecting An Attachment 3.48
            Installation 3.49
            Removal 3.49
                R
        Rail Transportability and GIC Clearance 2.79
        Rear Window Washer Switch 10.152
        Rear Wiper Switch/Motor 10.158
        Relays 2.61
            S
        Safety Information 1.3
            Hazard Statements 1.4
            Safety Alert Symbol 1.3
        Safety Instructions 1.5
            Equipment Hazards 1.5
            General Hazards 1.6
            Operational Hazards 1.6
            Personal Hazards 1.5
        Safety Practices
            Accident Prevention Tag Usage 1.4
            Emergency Exit Rear Window 1.6
            Hazard/Emergency Information Decals and/or Decal Plates 1.7
            Introduction 1.2
            Owners/Operators Manual 1.2
            Safety Information 1.3
            Safety Instructions 1.5
        Service Warnings
            Battery 10.10
            General 10.10
        Short Term Storage
            Maintenance Instructions 2.74
        Side Shift Cylinders
            (11K Carriage) 9.157
            (7K Carriage) 9.152
        Skylight Wiper Motor 10.154
        Skylight Wiper/Washer Switch 10.152
        Solar Panel 10.133
        Solargizer® Control Box 10.132
        Specifications
            Carriage Weights 2.14
            Electrical System 2.16
            Engine Performance Specifications 2.17
            Fluid and Lubricant Capacities 2.18
            Fork Ratings 2.21
            Hydraulic Cylinder Performance Specifications 2.15
            Hydraulic System 2.19
            Miscellaneous Specifications 2.20
            Performance Specifications 2.14
            Tamper Proofing 2.21
            Tires 2.20
            Vehicle Dimensions 2.12
            Vehicle Weights 2.14
        Stabilizer Brake Switch 10.180
        Stabil-TRAK™ Circuit Operation and Troubleshooting
            Hydraulic Circuit Operation
            Hydraulic Troubleshooting
            Stabilizer Cylinder Oil Flow 11.33
            Troubleshooting Symptom Chart 11.32
        Stabil-TRAK™ Electrical Circuit
            Not in FREE PIVOT Mode when Boom below 40˚ 11.14
            Not in LOCKED Mode when Boom above 40˚ 11.26
            Not in SLOW PIVOT Mode when Boom above 40˚ 11.20
        Stabil-TRAK™ System
            Circuit Operation and Troubleshooting 11.32
            Component Terminology 11.2
            Description 11.3
            Electrical Circuit Operation and Troubleshooting 11.8
            Operation 11.4
            Solenoid Valves 11.6
            Stabil-TRAK™ System Test 11.46
            Test Instructions 2.88
            Test Procedures 2.88
            Understanding the Stabil-TRAK™ System 11.4
        Stabil-TRAK™ System Test 2.88
        Standard Practices
            Capscrews and Metric Parts 8.6
            Cleanliness 8.6
            Gaskets and O-rings 8.6
            Left & Right Sides of Engine 8.6
        Starter 10.114
        Starting Circuit 10.113
        Steer Indexing Procedure 9.70
        Steer Select Valve
            Three-Mode Steer 4.8, 9.108
        Switches and Solenoids
            Attachment Tilt Mode Switch 10.189
            Engine Block Heater 10.202
            Engine Coolant High Temperature Sender 10.197
            Fuel Level Gauge 10.200
            Fuel Level Sender 10.200
            Hourmeter 10.202
            Hydraulic Oil Filter Pressure Switch 10.173
            Hydraulic Oil Temperature Switch 10.175
            Ignition Switch 10.170
            Joystick 10.191
            Logic Board Panel 10.195
            Parking Brake Switch 10.176
            Stabilizer Brake Switch 10.180
            Transmission Disconnect Switch 10.178
            Transmission Shift Control Switch 10.183
            Transmission Solenoid Valves 10.184
            Transmission Temperature Sender 10.198
                T
        Throttle Position Sensor 10.143
        Tiedown Locations 2.78
        Torques
            Bolts and Nuts 2.7
            Fasteners 2.7
            SAE Flat Face 0-Ring Seal Hydraulic Fittings 2.8
            Straight Thread O-ring Fitting (Non-Adjustable) 2.7
        Towing a Disabled Vehicle Short Distances
            Emergency Operations 2.83
        Transfer Case
            Description 6.4
            Further Information 6.5
            Inspection and Service 6.6
            Installation 6.9
            Internal Transfer Case Repair 6.9
            Maintenance 6.6
            Operation 6.4
            Removal 6.6
            Serial Number Plate 6.5
            Specifications 6.5
            Technical Data 6.5
        Transfer Case and Drive Shafts
            Component Terminology 6.2
            Drive Shafts 6.12
            General Information 6.4
            Transfer Case 6.4
            Troubleshooting 6.21
        Transfer Case Oil
            Maintenance Instructions 2.54
        Transmission
            After Service or Replacement 7.18
            General Specifications 7.4
            Inspection and Internal Repair 7.11
            Installation 7.12
            Lubrication 7.4
            Performance Specifications 7.4
            Related Fuse Ratings, Amps 7.4
            Removal 7.6
        Transmission Disconnect Switch 10.178
        Transmission Gear Selection Troubleshooting
            Forward First Gear Circuit 10.91
            Forward Fourth Gear Circuit 10.94
            Forward Second Gear Circuit 10.92
            Forward Third Gear Circuit 10.93
            Reverse First Gear Circuit 10.95
            Reverse Second Gear Circuit 10.96
            Reverse Third Gear Circuit 10.97
        Transmission Maintenance
            Introduction 7.4
            Schedule 7.5
        Transmission Oil and Filter
            Maintenance Instructions 2.47
        Transmission Shift Control Switch 10.183
        Transmission Solenoid Valves 10.184
        Transmission Temperature Sender 10.198
        Transmission: ZF 4 WG-98 TS
            Component Terminology 7.2
            Description 7.3
            Maintenance 7.4
            Operation 7.3
            Replacement 7.5
            Serial Number 7.3
            Specifications 7.4
            Towing a Disabled Vehicle 7.18
            Troubleshooting 7.19
        Transport
            Maintenance Instructions 2.78
        Troubleshooting
            Stabil-TRAK™ Electrical Circuit 11.8
            Transfer Case and Drive Shaft 6.21
            Transfer Case Internal Component 6.23
            Transmission 7.19
        Truck Transportability 2.79
            V
        Valves and Manifolds
            Joystick Valve 9.104
            Main Control Valve 9.87
            Pilot Select Manifold 9.99
            Power Steering Valve 9.107
            Secondary Function Manifold 9.102
            Service Brake Valve 9.104
            Steer Select Valve (Three-Mode Steer) 4.8, 9.108
            Unloader Valve 9.84
            Valve Plate Assembly 9.86
                W
        Warning Devices 10.134
        Warning Indicator Lights 10.134
            Alternator Charging 10.135
            Engine Air Filter Restriction 10.135
            Engine Oil Pressure 10.135
            Hydraulic Oil Filter Restriction 10.135
            Hydraulic Oil Temperature 10.134
            Low Brake Pressure 10.135
            Transmission Temperature 10.134
        Wheel End Oil
            Maintenance Instructions 2.52
        Wheels and Tires
            Installing Wheel and Tire Assembly onto Vehicle 5.18
            Maintenance Instructions 2.56
            Removing Wheel and Tire Assembly from Vehicle 5.16
            Wheel Cleaning 5.17
            Wheel Inspection and Replacement 5.17
        Windshield Washer Switch 10.150
        Windshield/Skylight/Rear Window Washer Reservoir w/Pump 10.156
        Wiring Harnesses
            Cleaning and Drying 10.12
            Disassembly 10.12
            Inspection and Repair 10.12
            Installation 10.12
            Removal and Replacement 10.12
            Wire Code and Color 10.12
            
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