Skytrak MMV Owner's/Operator's Manual
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Skytrak MMV Owner's/Operator's Manual

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TM 10794B-12/1
OWNERS/OPERATORS
MANUAL
Model MMV
(S/N MV201 & After)
(Tier 2)
OM0652
Keep this manual with the vehicle at all times.
8990504
PCN 500 107943 00
Printed in U.S .A. 10/11

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Summary of Contents for Skytrak MMV

  • Page 1 TM 10794B-12/1 OWNERS/OPERATORS MANUAL Model MMV (S/N MV201 & After) (Tier 2) OM0652 Keep this manual with the vehicle at all times. 8990504 PCN 500 107943 00 Printed in U.S .A. 10/11...
  • Page 2 WARNING: Improper operation of this vehicle can cause injury or death. Only trained and authorized operators should operate this vehicle. Before starting the engine, do the following: 1. Read this owner/operators manual. 2. Read all the safety decals on the vehicle. 3.
  • Page 3 Revision Log Revision Log 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. 8990504...
  • Page 4 Revision Log 8990504...

  • Page 5: Table Of Contents

    Table of Contents Revision Log 3.Closed Cab Air Filters...147 4.Engine Cooling System ..148 Introduction 5.Engine Oil and Filter .....152 The Manual........2 6.Engine Fuel System....157 Replacement Parts ......2 7.Engine Fan Belt ....162 Reports ..........2 8.Air Conditioner Disclaimer........3 Compressor Belt ....163 Safety Practices 9.Hydraulic Oil and Filter ..164 Hazard Classification System..3 10.Transmission Oil...

  • Page 6: The Manual

    To guarantee full warranty service, make sure your Authorized Service Center (ASC) has returned the business reply card of this form to JLG. Model MMV Rev. 10/11...

  • Page 7: Disclaimer

    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...
  • Page 8 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...

  • Page 9: Accident Prevention Tags

    In addition, make sure that the new operator has completed a walk-around inspection of the vehicle, is familiar with all decals on the vehicle, and has demonstrated the correct use of all controls. Model MMV Rev. 10/11...

  • Page 10: Instructional Symbols

    Safety Practices Instructional Symbols The following symbol definitions will help you understand all hazard related decals used on this vehicle. OP0330 Safety Alert Symbol OH2100 Read Operator’s Manual OH2090 Fasten Seat Belt Model MMV Rev. 10/11...

  • Page 11: Hazard Symbols

    Can Result In Death Cause Death Or Or Entangle Or Serious Injury Serious Injury OH3160 OH2161 AVOID CRUSHING, Falling Off FALLING OFF ATTACHMENT Vehicle Can Cause Death Or Can Result In Death Or Serious Serious Injury Injury Model MMV Rev. 10/11...

  • Page 12: Avoidance Symbols

    Rotating Fan Blades Boom Raised OH2290 OH2280 Maintain Proper Air Do Not Raise Boom Pressure In Tire While On A Slope OU1460 DO NOT Use Ether Or Other High Energy Starting Aids. Engine Equipped With Grid Heating System. Model MMV Rev. 10/11...

  • Page 13: Avoidance Symbols (Cont'd)

    DO NOT JUMP Use Only Compliant Work Platforms To Raise Or Lower • Brace Yourself and Stay Personnel With Vehicle • Keep Seat Belt Fastened • Hold On Firmly • Lean Away From The Point Of Impact Model MMV Rev. 10/11...

  • Page 14: Personal Considerations

    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...
  • Page 15 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. Model MMV Rev. 10/11...
  • Page 16 • Internal Contact — Drink large quantities of water. Follow with Milk of Magnesia, beaten egg or vegetable oil. Get medical attention immediately. IMPORTANT! In case of internal contact, DO NOT give fluids that would induce vomiting! Model MMV Rev. 10/11...
  • Page 17 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...

  • Page 18: Operational Considerations

    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...
  • Page 19 NEVER operate this vehicle in an area where overhead power lines, overhead or underground cables, or other power sources may exist without first requesting that the appropriate power or utility company de- energize the lines, or take other suitable precautions. OS0063 Model MMV Rev. 10/11...
  • Page 20 CRUSHING, falling off vehicle can cause death or serious injury Allow no riders Lift or lower personnel DO NOT TRAVEL only in a compliant with personnel in work platform. a work platform. OH3180 4110389 OU0620 Model MMV Rev. 10/11...
  • Page 21 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. OU09201 Model MMV Rev. 10/11...
  • Page 22 • 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...
  • Page 23 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...

  • Page 24: Equipment Considerations

    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. CAUTION ENGINE OVERHEATING can occur. Consult Operator Manual for coolant filling procedure. OM2290 4110468 Model MMV Rev. 10/11...
  • Page 25 Full Tire Pressure Load Chart Booklet - 60 psi (414 kPa) 6623944 Reduced Tire Pressure Load Chart Booklet - 45 psi (310 kPa) 6623997 Reduced Tire Pressure 4110137 Tipover Danger 4110358 Do Not Jump Danger 4110361 Safety Instructions Model MMV Rev. 10/11...
  • Page 26 Boom Angle Indicator 4110463 Ether Start Warning 4110468 Coolant Filling Caution 1001092290 Machine Identification Plate 1706549 Universal ID Plate 6623390 MMV Serial Number Plate 4110306 Shipping Data Plate 1001121649 Slave Decal, 24V DC 3576086 Engine Identification Plate Model MMV Rev. 10/11...

  • Page 27: Operator Controls

    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. OM1770 Model MMV Rev. 10/11...
  • Page 28 OFF position (2) — The entire electrical system is shut down. RUN position (3) — All controls and indicators are operable. START position (4) — Engages starter motor to crank the engine when the parking brake switch is engaged and the transmission is in NEUTRAL. OM1780 Model MMV Rev. 10/11...
  • Page 29 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. OM1790 Model MMV Rev. 10/11...
  • Page 30 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. OU0381 Model MMV Rev. 10/11...
  • Page 31 The battery disconnect switch (1) is located in the engine compartment. OM3630 This switch, when turned to the "OFF" position, disconnects the circuit between the batteries and the electrical system. The battery disconnect switch should be turned to the "OFF" position during periods of extended storage. Model MMV Rev. 10/11...
  • Page 32 NEUTRAL position and move the Neutral Lock Lever (2) to the (N) NEUTRAL LOCK position. To unlock, move the Neutral Lock Lever to the (D) DRIVE position. N = NEUTRAL LOCK ....all the way LEFT OT0570 D = DRIVE ........all the way RIGHT OT0580 Model MMV Rev. 10/11...
  • Page 33 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) NEUTRAL position to permit engine starting. Model MMV Rev. 10/11...
  • Page 34 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 are guidelines only. Always use good judgement when traveling with a load. Model MMV Rev. 10/11...
  • Page 35 The Attachment Tilt Mode Switch (2) has two positions which allow the operator to chose between the Lift/Lower function OS2120 and the Extend/Retract function accompanying the Attachment Tilt capability. For detailed information, see “Multi-Function Joystick Operation” starting on page 32. OM1830 Model MMV Rev. 10/11...
  • Page 36 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...
  • Page 37 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 OS0600 OM0660 Model MMV Rev. 10/11...
  • Page 38 For the attachment tilt mode covered in Mode 2A and 2B on the following pages, use the attachment tilt mode switch (1) located in the upper bank of switches to the right of the steering wheel. OM1830 Model MMV Rev. 10/11...
  • Page 39 (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 Boom Retract ......move handle to the left OS0671 OM0680 Model MMV Rev. 10/11...
  • Page 40 (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 OS0610 OM0700 Model MMV Rev. 10/11...
  • Page 41 (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 OS0611 OM0710 Model MMV Rev. 10/11...

  • Page 42: 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...
  • Page 43 4. To release the belt latch, depress the red button (5) and pull the free end (3) from the buckle (4). Model MMV Rev. 10/11...
  • Page 44 Turn counter-clockwise to reduce the stiffness. Backrest Angle Adjustment The angle of the seat backrest can be adjusted to suit the operator. Move the lever (3) located on the left side the seat backrest to adjust the angle. OM1840 Model MMV Rev. 10/11...
  • Page 45 - 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 system is activated these lights will not operate. OM1830 Model MMV Rev. 10/11...
  • Page 46 When the high beam 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. OM1850 Model MMV Rev. 10/11...
  • Page 47 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 OM0850 OM1830 Model MMV Rev. 10/11...
  • Page 48 To activate the emergency OS1920 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. OM1860 Model MMV Rev. 10/11...
  • Page 49 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. OU1190 Model MMV Rev. 10/11...
  • Page 50 • 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). OM2090 Model MMV Rev. 10/11...
  • Page 51 OH2591 • Place the rocker switch in the MIDDLE position to operate the wiper at LOW speed. OH2601 • Push the BOTTOM of the rocker switch in to operate the wiper at HIGH speed. OH2611 OM1830 Model MMV Rev. 10/11...
  • Page 52 • Release the switch to deactivate the washer control. OH2591 • Press and hold the BOTTOM of the rocker switch in to activate the windshield washer. The rocker switch is spring loaded and will return to the OFF OH2611 position when released. OM1830 Model MMV Rev. 10/11...
  • Page 53 Rear Window Wiper The rear window wiper rocker switch (3) is located on the motor housing of the rear OM1530 wiper. The switch has two positions; wiper ON (4) and wiper OFF (5). OU0170 Model MMV Rev. 10/11...
  • Page 54 (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. OM1830 Model MMV Rev. 10/11...
  • Page 55 • turn temperature control knob (4) to the far left position (BLUE = COOL), • direct desired air flow by adjusting vent louvers, • turn fan control (2) to “3” (5) to assure rapid cool-down. OU0930 Model MMV Rev. 10/11...
  • Page 56 Cummins Customer Assistance Center at 1-800-343-7357. 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...
  • Page 57 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...

  • Page 58: Front Dash Panel

    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...
  • Page 59 NOTE: This indicator light may come ON when the engine is running to indi- cate 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...
  • Page 60 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...
  • Page 61 Hydraulic Oil Filter Restriction Warning Indicator (6) This light illuminates when a restricted OT1030 hydraulic oil filter is detected. If the light is ON, service the hydraulic oil filter. °F RPM X 100 °C r/min 0000000 OU0010 Model MMV Rev. 10/11...
  • Page 62 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. °F RPM X 100 °C r/min 0000000 OU0010 Model MMV Rev. 10/11...
  • Page 63 210° F (99° C) the engine coolant is too hot. Idle the engine 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...
  • Page 64 Turn Signal Indicator (2) The turn signal indicator light OH2510 will illuminate and flash when the turn signals are activated in either direction or when the hazard lights have been activated. °F RPM X 100 °C r/min 0000000 OU0010 Model MMV Rev. 10/11...

  • Page 65: Instruments And Indicators

    -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 determine the boom angle when reading the capacity chart (see “Using the Capacity Chart” on page 92). OM0961 Model MMV Rev. 10/11...
  • Page 66 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 hood. OS1470 OM1670 Model MMV Rev. 10/11...
  • Page 67 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...
  • Page 68 Operation 100% TEST OM1890 Model MMV Rev. 10/11...
  • Page 69 Release the test button when the preferred combination occurs. The combinations are: • 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...

  • Page 70: Pre-Operation Inspection

    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 conditioner con- denser located at the rear of the frame. Clean the fins as needed. Model MMV Rev. 10/11...

  • Page 71: Normal Starting

    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...

  • Page 72: Cold Starting

    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...
  • Page 73 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...

  • Page 74: Slave Starting

    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. OM3640 Model MMV Rev. 10/11...

  • Page 75: Refueling

    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...
  • Page 76 “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...

  • Page 77: Operating

    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). °F RPM X 100 °C r/min 0000000 OM1910 Model MMV Rev. 10/11...
  • Page 78 • Placing the travel select lever in (N) NEUTRAL • Depressing and holding the service brake pedal The frame sway control will function slower than normal in this mode. °F RPM X 100 °C r/min 0000000 OM1920 Model MMV Rev. 10/11...
  • Page 79 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. °F RPM X 100 °C r/min 0000000 OM1930 Model MMV Rev. 10/11...
  • Page 80 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). OM1810 Model MMV Rev. 10/11...
  • Page 81 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...
  • Page 82 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. °F RPM X 100 °C r/min 0000000 OM1800 Model MMV Rev. 10/11...
  • Page 83 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. OM1790 Model MMV Rev. 10/11...
  • Page 84 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. OS0280 Model MMV Rev. 10/11...
  • Page 85 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. OS0290 Model MMV Rev. 10/11...
  • Page 86 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. OS0310 Model MMV Rev. 10/11...
  • Page 87 Always use the frame sway control to level the vehicle before raising the boom above horizontal. If the vehicle cannot be leveled using the frame sway control, reposition the vehicle. Model MMV Rev. 10/11...

  • Page 88: Carriages

    3. Exit the vehicle using both hand holds. 4. Remove the spring clip pin (3) from the quick attach pin (4) and pull the pin out of the bottom of the quick attach link (5). OM0970 Model MMV Rev. 10/11...
  • Page 89 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 attachment pivot pins have disconnected from the attachment. Model MMV Rev. 10/11...
  • Page 90 7. Insert the quick attach pin (6) completely through the attachment and the quick attach link (7). Insert the spring clip pin (8) through the quick attach pin. OM0970 Model MMV Rev. 10/11...
  • Page 91 Death or serious personal injury could result if the belt is not securely fas- tened. 10. Return to the cab, fasten the seat belt and resume operation. Model MMV Rev. 10/11...
  • Page 92 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. OM1940 Model MMV Rev. 10/11...
  • Page 93 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...
  • Page 94 4. Maneuver the vehicle so the 7K carriage forks (6) go in the intended openings (5) in the 11K carriage. The back of the 11K car- riage must be resting against the vertical area of the 7K forks. Model MMV Rev. 10/11...
  • Page 95 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. OM1880 Model MMV Rev. 10/11...

  • Page 96: Using The Capacity Chart

    Choose the correct load chart for the size carriage being used and the tire pressure being utilized. OM1950 Model MMV Rev. 10/11...
  • Page 97 (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...

  • Page 98: Load Capacity To Travel Speed Tables

    0 to 6 mph (0 to 9,7 km/h) 4,500 to 11,000 lbs Improved 0 to 6 mph (0 to 9,7 km/h) (2.041 to 4.989 kg) Rough 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...
  • Page 99 2,000 to 5,500 lbs Improved 0 to 6 mph (0 to 9,7 km/h) (907 to 2.495 kg) Rough 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...
  • Page 100 Up to 2,000 lbs Improved 0 to 6 mph (0 to 9,7 km/h) (up to 907 kg) Rough 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...
  • Page 101 60 psi (414 kPa) or 45 psi (310 kPa) reduced tire pressures, the speed of the vehicle cannot exceed 6 mph (9,7 km/h). Refer to “Load Capacity To Travel Speed Tables” begining on page 94 for proper load capacity to travel speeds. Model MMV Rev. 10/11...
  • Page 102 87 psi (600 kPa) - Full Tire Pressure OM2260 4110435 Use with OmniQuip 24" Load Center Carriage 0 ft 69° 60° 50° 9000 40° 30° 11000 20° 10° 24" 0° 0 ft -3° ASME B56.6b -1998 OM1970 Model MMV Rev. 10/11...
  • Page 103 87 psi (600 kPa) - Full Tire Pressure OM2260 0 ft 69° 60° 50° 40° 7000 30° 20° 10° 48" 0° 0 ft -3° ASME B56.6b -1998 12.5 19.5 Use with OmniQuip 48" Load Center Carriage 4110436 OM1980 Model MMV Rev. 10/11...
  • Page 104 60 psi (414 kPa) - Reduced Tire Pressure OM2250 4110467 Use with OmniQuip 24" Load Center Carriage 0 ft 69° 50° 3° 3° 40° 30° 20° 10° 24" 0° 0 ft -3° ASME B56.6b -1998 60 psi (414 kPa) OM2270 Model MMV Rev. 10/11...
  • Page 105 60 psi (414 kPa) - Reduced Tire Pressure OM2250 60 psi (414 kPa) 0 ft 69° 50° 3° 3° 40° 30° 20° 10° 48" 0° 0 ft -3° ASME B56.6b -1998 Use with OmniQuip 48" Load Center Carriage 4110466 OM2280 Model MMV Rev. 10/11...
  • Page 106 45 psi (310 kPa) - Reduced Tire Pressure OM2250 4110472 Use with OmniQuip 24" Load Center Carriage 0 ft 69° 60° 50° 3° 3° 30° 20° 2000 lb 10° 24" 0° 0 ft -3° ASME B56.6b -1998 45 psi (310 kPa) OM2300 Model MMV Rev. 10/11...
  • Page 107 45 psi (310 kPa) - Reduced Tire Pressure OM2250 45 psi (310 kPa) 0 ft 69° 60° 50° 3° 3° 30° 20° 10° 48" 0° 0 ft -3° ASME B56.6b -1998 Use with OmniQuip 48" Load Center Carriage 4110471 OM2310 Model MMV Rev. 10/11...

  • Page 108: Fork Rating

    When the load rating of the vehicle differs from the load capacity of the forks, the lower value becomes the overall load capacity. Model MMV Rev. 10/11...

  • Page 109: How To Pick, Carry & Place A Load

    LMI system is malfunctioning or out of calibration. Contact your local JLG Authorized Service Center (ASC) or refer to the MMV Service Manual for the proper procedure to recalibrate or repair the system. NEVER attempt to work with a load when the LMI system is malfunctioning.
  • Page 110 Lower the boom until the pallet rests in position and the forks are free to retract. Model MMV Rev. 10/11...

  • Page 111: Elevating Personnel

    3. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to the (N) NEUTRAL LOCK position and engage the parking brake switch. 4. Shut the engine OFF. 5. Exit the cab and go to the front of the boom. Model MMV Rev. 10/11...
  • Page 112 Disconnect the RED (1) then the BLACK (2) on the left side. Dis- connect the GREEN (3) then the YELLOW (4) on the right side. 7. Install the protective caps (5) on all four quick disconnects. OM0930 Model MMV Rev. 10/11...
  • Page 113 Prevent the platform from inadvertent pivoting. 7. The platform must have a restraining means such as a guardrail or a means of securing personnel such as a body belt or lanyard for each occupant of the platform. Model MMV Rev. 10/11...
  • Page 114 The combined mass (weight in pounds) of the platform, load and personnel shall not exceed one-third (33%) of the capacity of the related load center position indicated on the capacity chart. Refer to “Using the Capacity Chart” on page 92. Model MMV Rev. 10/11...
  • Page 115 14. Provide any overhead protection device as required by worksite conditions or if requested by the user of the platform. Model MMV Rev. 10/11...
  • Page 116 IMPORTANT! Make sure that required restraining equipment such as railings, chains, cable, body belts with lanyards, etc. are in place and properly used. Never use railings, planks, ladders, etc. on the platform for the purpose of achieving additional reach or height. Model MMV Rev. 10/11...

  • Page 117: Shut-Off

    3. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to the (N) NEUTRAL LOCK position and engage the parking brake switch. 4. Lower the boom and ground the attachment. 5. Turn the ignition switch to the OFF position. Model MMV Rev. 10/11...

  • Page 118: Towing A Disabled Vehicle

    BLOCK ALL FOUR WHEELS. Failure to do so could result in death or serious injury from vehicle roll-away. 4. Block all four wheels to prevent any unexpected movement of the vehicle after the parking brake is disabled. Model MMV Rev. 10/11...
  • Page 119 ON position. Contact with moving parts can cause death or serious personal injury. 9. Unlatch and open the rear door. Connect the steer cylinder cross- over tow hoses (4) together. The two hoses are located inside the rear of the frame. Model MMV Rev. 10/11...
  • Page 120 13. Carefully remove the blocks from the four wheels of the vehicle. 14. Have an operator seated in the seat. 15. The vehicle can now be towed out of the way using the pintle hook provided. Tow the vehicle at a very slow speed! OM1080 Model MMV Rev. 10/11...
  • Page 121 16. Before returning the vehicle to service, disconnect the steer cylin- der crossover hoses (1) by removing the “male” nipple (2) from the “female” coupler (3). Re-install both dust caps (4 and 5). Perform the “Four Wheel Steer Indexing Procedure” on page 244. OM1080 Model MMV Rev. 10/11...
  • Page 122 5. Secure the unattached end of each driveshaft (9) in the hanger hooks (10) provided underneath the frame of the vehicle. Rotate the hanger hooks into position to hold the driveshaft. The hanger hooks have spring tension applied to hold them in position. MM2220 Model MMV Rev. 10/11...
  • Page 123 DO NOT exceed 650 psi (45 bar). CAUTION: DO NOT exceed 650 psi (45 bar) when pressurizing the park brake. Applying too much pressure may damage the brake seals. OM2140 Model MMV Rev. 10/11...
  • Page 124 Couple the quick disconnects together. 13. With the crossover hoses (4) coupled together, the rear wheels will be free to steer, thus “tracking” as the vehicle is being towed. 14. Close and latch the rear door. OM1080 Model MMV Rev. 10/11...
  • Page 125 19. Before placing the vehicle back into service, disconnect the steer cylinder crossover hoses (1) by removing the “male” nipple (2) from the “female” coupler (3). Re-install both dust caps (4 and 5). Model MMV Rev. 10/11...
  • Page 126 Torque the M12 bolts to 156 lb-ft (212 Nm). Rotate the driveshaft hanger hooks (10) out of the way and install the driveshafts to the front and rear axles. MM2220 21. Perform the “Four Wheel Steer Indexing Procedure” on page 244. Model MMV Rev. 10/11...

  • Page 127: Emergency Boom Lowering

    Refer to “Accident Prevention Tags” on page 5. Actual accident prevention tags can be found as the last page of this manual. If you do not have a safety tag, place tape over the ignition switch. Model MMV Rev. 10/11...
  • Page 128 Only resort to Steps 3 & 4 when absolutely necessary. IMPORTANT! Be aware that the boom must first be retracted and then lowered to avoid vehicle tipover. Model MMV Rev. 10/11...
  • Page 129 • Boom Lower Line - Lift Cylinder to Bulkhead (3) • Boom Lift Line - Lift Cylinder to Bulkhead (4) • Boom Lift Line - Bulkhead to Control Valve (5) • Boom Lower Line - Bulkhead to Control Valve (6) OT0171 Model MMV Rev. 10/11...
  • Page 130 BOOM LOWER LINE (LIFT CYLINDER TO STEP 1 STEP 3 BULKHEAD) BOOM LOWER LINE (BULKHEAD TO STEP 1 STEP 3 CONTROL VALVE) BOOM EXTEND STEP 1 STEP 2 LINE BOOM RETRACT STEP 1 STEP 4 LINE Model MMV Rev. 10/11...
  • Page 131 8. Return to the cab, fasten your seat belt and start the engine. 9. Tilt the carriage upward if necessary for clearance before retracting the boom. 10. Slowly retract the boom. 11. Slowly lower the boom and ground the carriage. Model MMV Rev. 10/11...
  • Page 132 14. Return to the cab, fasten your seat belt and start the engine. 15. Cycle the lift/lower and extend/retract cylinders several times to bleed air from the system. Check for leaks. 16. Recheck the hydraulic oil level. Add oil if necessary. OT0171 Model MMV Rev. 10/11...
  • Page 133 12. Cycle the lift/lower cylinder several times to bleed air from the sys- tem. Check for leaks. 13. Recheck the hydraulic oil level. Add oil if necessary. 14. Transfer any waste oil to a container with a cover and label as used oil. Dispose of properly. Model MMV Rev. 10/11...
  • Page 134 Emergency Operations OT0651 Model MMV Rev. 10/11...
  • Page 135 (the failed hose could be used) directing the oil into the drain container. 8. Check the hydraulic oil level and add oil if needed. 9. Remove the blocking or support from the outer boom. 10. Return to the cab, fasten your seat belt and start the engine. Model MMV Rev. 10/11...
  • Page 136 Emergency Operations OS2161 OS2170 IMPORTANT! Have the vehicle serviced and hoses replaced as soon as the boom has been lowered and the vehicle is in a secure location. Model MMV Rev. 10/11...
  • Page 137 18. Cycle the lift/lower cylinder several times to bleed air from the sys- tem. Check for leaks. 19. Transfer the waste oil to a container with a cover and label as used oil. Dispose of properly. 20. Recheck the hydraulic oil level. Add oil if necessary. Model MMV Rev. 10/11...
  • Page 138 3. If the load is in a position where it can be removed safely, com- pletely remove the load from the carriage, otherwise leave the load in place. 4. Place a 10 gallon (38 liter) container under the vehicle to catch any hydraulic oil that will escape during this procedure. Model MMV Rev. 10/11...
  • Page 139 16. Cycle the extend/retract cylinder several times to bleed air from the system. Check for leaks. 17. Transfer the waste oil to a container with a cover and label as used oil. Dispose of properly. 18. Recheck the hydraulic oil level. Add if necessary. Model MMV Rev. 10/11...
  • Page 140 Emergency Operations OT0182 OT0191 Model MMV Rev. 10/11...

  • Page 141: Introduction

    OS1171 WARNING: DO NOT perform service or maintenance on the vehicle with the engine running, with the exception of the transmission level check. Contact with moving parts can cause death or serious personal injury. Model MMV Rev. 10/11...

  • Page 142: Maintenance Schedule And Checklist

    At First 50 Hours of Use OM1460 430-470 (583-637) Change Engine Oil Change Change Hydraulic Check and Filter Transmission Filter Wheel Lug Filter Nut Torque Paragraph Ref. OT1080 Change Axle Oil Change Wheel End Oil Change Transfer Case Oil Paragraph Ref. Model MMV Rev. 10/11...
  • Page 143 Oil and Filter Oil Level Fittings Fuel Filter Paragraph 6B & 6C Ref. OM1060 Check Wheel End Check Axle Inspect Extend Chains Oil Level Oil Level Paragraph Ref. 500 Hour Intervals OM2180 Change Air Filter Paragraph Ref. Model MMV Rev. 10/11...
  • Page 144 Axle Oil Wheel End Oil Transfer Case Oil Paragraph Ref. OM1490 Check Axle Check Check Air Lubricate Boom Chains Brake Discs Fan Belt Intake System Paragraph Ref. 2000 Hour Intervals OT1140 Change Engine Coolant Paragraph Ref. Model MMV Rev. 10/11...

  • Page 145: Lubrication Points

    Apply Teflon Lube as needed to keep forks sliding side to side smoothly, when putting vehicle into storage or when Teflon Lube appears to be worn off or rust starts to appear on the fork shaft or wear bar. OM0940 Model MMV Rev. 10/11...
  • Page 146 General Maintenance OM1131 Model MMV Rev. 10/11...

  • Page 147: Air Cleaner

    CAUTION: NEVER run the engine with only the inner safety element installed. Severe engine damage will result from dust entering the engine. °F RPM X 100 °C r/min 0000000 OU0010 Model MMV Rev. 10/11...
  • Page 148 General Maintenance To change elements: 1. Pull the air cleaner cover lock (2) OUT, turn the air cleaner cover (3) counter-clockwise and remove the cover from the air cleaner canis- ter (4). OM1990 Model MMV Rev. 10/11...
  • Page 149 General Maintenance 2. Remove the primary element (1). Inspect the element for damage. Damaged elements should never be reused. OM2000 Model MMV Rev. 10/11...
  • Page 150 If dirt or debris are allowed to enter the combustion chamber, they can severely damage the engine. If necessary, tighten or replace parts to prevent air intake system leakage. Model MMV Rev. 10/11...

  • Page 151: Closed Cab Air Filters

    The filter should be replaced at 250 hour intervals under normal operating conditions and at 50 hour intervals under extreme operating conditions. NOTE: Correctly position the filter so the air flow is directed into the cab. Model MMV Rev. 10/11...

  • Page 152: Engine Cooling System

    1/2 to 3/4 full. When the coolant is cool, the bottle should be 1/4 to 1/2 full. Add coolant (50/50 mixture of ethylene glycol and water) as required through the overflow bottle. OM2210 Model MMV Rev. 10/11...
  • Page 153 Wear protective clothing and safety glasses. 3. Slowly turn the radiator cap (1) located in the upper radiator hose to the first stop and allow any pressure to escape. Remove the radia- tor cap. Model MMV Rev. 10/11...
  • Page 154 8. Reattach the overflow hose to the radiator fill neck. 9. Turn the ignition to RUN and turn the heat control knob to the HOT position to open the heat valve. Model MMV Rev. 10/11...
  • Page 155 6. Allow the engine to cool. 7. The overflow bottle should be 1/4 to 1/2 full. If not, fill to this level with a 50/50 mixture of ethylene glycol and water. 8. Close and latch the engine cover. OM2230 Model MMV Rev. 10/11...

  • Page 156: Engine Oil And Filter

    (N) NEUTRAL, move the neu- tral lock lever to the (N) NEUTRAL LOCK position, engage the parking brake switch and shut off the engine. 2. Unlatch and open the engine cover. Model MMV Rev. 10/11...
  • Page 157 4. Place a receptacle under the engines oil pan drain hose (4). The hose is located under the engine up behind the hydraulic oil reser- voir. 5. Lift the petcock lever (5) up and turn counterclockwise to OPEN and drain the oil from the engine oil pan. Model MMV Rev. 10/11...
  • Page 158 8. Apply a thin coat of clean engine oil to the new filter mating surface. 9. Install the new oil filter and hand tighten. Use an oil filter wrench or strap to tighten the filter down another 1/4 to 1/2 turn. OM2020 Model MMV Rev. 10/11...
  • Page 159 General Maintenance OM2010 10. Turn the oil drain petcock lever (1) clockwise and lock into the CLOSED position. The petcock lever is spring loaded and will lock in the CLOSED position. OU1280 Model MMV Rev. 10/11...
  • Page 160 1. Unlatch and open the engine hood. 2. Locate the oil sample valve (4) on the mounting bracket next to the remote fuel filter. 3. After oil sample has been taken, close and latch the engine hood. OM2240 Model MMV Rev. 10/11...

  • Page 161: Engine Fuel System

    (2) and allow all the water to drain into a container until clear fuel is visible. Dispose of properly. Tighten drain cock after draining. Close and latch engine cover. OM3650 Model MMV Rev. 10/11...
  • Page 162 They are: JP-5, JP-8 or Jet A-1. 7. Install the fuel-filled filter and hand tighten. DO NOT overtighten. NOTE: Mechanical over-tightening may distort the threads or damage the sealing ring. 8. Close and latch the engine cover. Model MMV Rev. 10/11...
  • Page 163 4. Install the new strainer with arrow (4) pointing toward the lift pump. 5. Assemble the hoses to the strainer and tighten the hose clamps. 6. Remove air from the fuel system (see “Bleeding Fuel System” on page 160). 7. Close and latch the engine cover. OM2160 Model MMV Rev. 10/11...
  • Page 164 (5) located on the filter head on the engine block. 2. Operate the hand plunger (6) on the lift pump (2) until fuel flowing from the fitting is free of air. 3. Tighten the vent screw (5) and torque to 7 lb-ft (9 Nm). Model MMV Rev. 10/11...
  • Page 165 6. Tighten the fitting. Torque to 22 lb-ft (30 Nm). 7. Repeat Steps 4-6 for each fitting until the engine runs smoothly. 8. With the engine running, visually check for leaks. Turn ignition switch OFF. OU0250 Model MMV Rev. 10/11...

  • Page 166: Engine Fan Belt

    Release the tensioner to apply tension on the belt. To hold the ten- sioner toward the center of the engine, insert a 3/8" breaker bar into the square hole (10) in the tensioner arm. 7. Close and latch the engine cover. OU0240 Model MMV Rev. 10/11...

  • Page 167: Air Conditioner Compressor Belt

    5. Adjust the tension on the belt by loosening the bolts (4) on the com- pressor bracket (5). Adjust the belt with the nut on the adjustment rod end (6). Tighten the compressor bracket bolts when adjustment is complete. 6. Close and latch the engine cover. OU1480 Model MMV Rev. 10/11...

  • Page 168: Hydraulic Oil And Filter

    (N) NEUTRAL, move the neutral lock lever to the (N) NEU- TRAL LOCK position and engage the parking brake switch. 2. Fully retract all hydraulic cylinders and shut off the engine. 3. Unlatch and open the engine cover. 4. Allow the hydraulic oil to cool. Model MMV Rev. 10/11...
  • Page 169 Hydraulic Oil/Temperature Range” on page 164. DO NOT overfill. DO NOT add oil through the hydraulic oil tank breather (3) located beside the suction hose fitting. 6. Reinstall the hydraulic oil fill cap (2). 7. Close and latch the engine cover. OM1071 OT0660 Model MMV Rev. 10/11...
  • Page 170 (N) NEUTRAL, move the neutral lock lever to the (N) NEU- TRAL LOCK position and engage the parking brake switch. 2. Fully retract all hydraulic cylinders and shut off the engine. 3. Unlatch and open the engine cover. Allow the oil to cool. Model MMV Rev. 10/11...
  • Page 171 (2) that secure the filter head to the hydraulic tank (3). OT0660 5. Rotate and remove the filter head (4). 6. Remove the seal (5) and the element (6) from the filter head (4). Dispose of properly. 7. Clean the filter head sealing surface. OM1610 Model MMV Rev. 10/11...
  • Page 172 (10) located beside the suction hose fitting. 12. Close and latch the engine cover. 13. Run vehicle and operate all hydraulic functions. Cycle all modes of controls to purge air from the system. 14. Check for leaks. Model MMV Rev. 10/11...

  • Page 173: Transmission Oil And Filter

    3. Remove the transmission dipstick (1). Check oil level. 4. Add oil to transmission as required to bring the level up to the full mark. Refer to the “Recommended Transmission Oil/Temperature Range” above for proper oil. Model MMV Rev. 10/11...
  • Page 174 (N) NEUTRAL, move the neutral lock lever to the (N) NEU- TRAL LOCK position, engage the parking brake switch and shut off the engine. 2. Unlatch and open the engine cover. Allow the engine and transmis- sion to cool. Model MMV Rev. 10/11...
  • Page 175 Range” on page 169. Re-install the dipstick. OM3650 8. Check the transmission level and add oil as required following the procedures outlined in “Transmission Oil Level Check” on page 169. 9. Close and latch the engine cover. Model MMV Rev. 10/11...

  • Page 176: Axle Oil

    1. Level the vehicle, ground the attachment, place the travel select lever in (N) NEUTRAL, move the neutral lock lever to the (N) NEU- TRAL LOCK position, engage the parking brake switch and shut off the engine. Model MMV Rev. 10/11...
  • Page 177 Interval Oil Change also inspect the brake disk wear. Refer to “Brake Disk Inspection” on page 175 and follow the inspection pro- cedure. After brake disk inspection is complete, reassemble the level plugs using new o-rings. Model MMV Rev. 10/11...
  • Page 178 Axle level is correct when oil is up to both level plugs (2). 8. Reassemble the level plugs (2) using new o-rings. 9. Re-install the axle fill plug (1) into axle housing. Model MMV Rev. 10/11...

  • Page 179: Brake Disk Inspection

    Watch the pressure gauge (3) while pumping pressure into the park brake system. DO NOT exceed 650 psi (45 bar). CAUTION: DO NOT exceed 650 psi (45 bar) when pressurizing the park brake. Applying too much pressure may damage the brake seals. Model MMV Rev. 10/11...
  • Page 180 General Maintenance OM2140 6. Working through the level plug hole (4), carefully use a screwdriver to spread the brake disks apart. IMPORTANT! DO NOT damage the surfaces of the brake disks when spreading the brake disks. MT2850 Model MMV Rev. 10/11...
  • Page 181 8. Repeat step 6 and step 7 for the other side of the axle. 9. Continue with step 6 of “B. Axle Oil Change” on page 173 MT2840 Model MMV Rev. 10/11...
  • Page 182 3. Repeat step 1 and step 2 for the other side of the axle. 4. Continue with step 6 of “B. Axle Oil Change” on page 173 Model MMV Rev. 10/11...

  • Page 183: Wheel End Oil

    TRAL, move the neutral lock lever to the (N) NEUTRAL LOCK posi- tion, engage the parking brake switch and shut off the engine. 3. Clean the area around the wheel end fill/drain plug (2). Slowly remove the plug. Check the oil level. Model MMV Rev. 10/11...
  • Page 184 OT0290 2. Ground the attachment, place the travel select lever in (N) NEU- TRAL, move the neutral lock lever to the (N) NEUTRAL LOCK posi- tion, engage the parking brake switch and shut off the engine. Model MMV Rev. 10/11...
  • Page 185 “Recommended Wheel End Oil/Temperature Range” on page 179 for proper oil. Wheel end capacity is approximately: Front Axle........1.7 quarts (1,6 liters) Rear Axle ........1.3 quarts (1,2 liters) 7. Clean and re-install the wheel end fill/drain plug (3). OT0280 Model MMV Rev. 10/11...

  • Page 186: Transfer Case Oil

    2. Clean the area around the transfer case oil fill/level plug (1). OM1720 3. Remove the oil fill/level plug (1) from the transfer case (2) and check the oil level. 4. Add oil as required through the oil fill/level hole (1). Bring the oil Model MMV Rev. 10/11...
  • Page 187 Refer to the “Recommended Transfer Case Oil/Temperature Range” on page 182 for proper oil. The transfer case capacity is 1.5 quarts (1,4 liters). 9. Clean and re-install the oil fill/level plug (1). Model MMV Rev. 10/11...
  • Page 188 4. Add oil as required through the oil fill/level hole (1). Bring the oil level up and even with the oil fill/level plug hole. 5. Clean and re-install the oil fill/level plug (1). Model MMV Rev. 10/11...
  • Page 189 8. Fill the transfer case with oil through the oil fill/level hole (1). Fill until the level is up to and even with the oil fill/level plug hole. The transfer case capacity is 1.5 quarts (1,4 liters). 9. Clean and re-install the oil fill/level plug (1). Model MMV Rev. 10/11...

  • Page 190: Wheels And Tires

    4. Refer to “Emergency Tire Inflation System” on page 188 for proper procedure as if a tire or tires must be filled with the vehicle away from a normal inflation system. 5. DO NOT overinflate. 6. Replace the valve stem cap. Model MMV Rev. 10/11...
  • Page 191 IMPORTANT! The specified size and star rating for this vehicle is 15.5R25, L-2, 2 Star. Make sure any replacement tire is of the same size and star rating. DO NOT use lower star rated tires on this vehicle. Model MMV Rev. 10/11...

  • Page 192: Emergency Tire Inflation System

    Locate the access hole (1) in the plate under the cab and open the petcock (2) on the bottom of the tank (3) to remove any water that has accumulated inside the tank. Close the petcock after all water has been removed. OM2070 Model MMV Rev. 10/11...
  • Page 193 2. Shut the engine OFF. 3. The tire inflation hose (4) is stored on the rear wall of the cab behind the seat (5). The hose is coiled up and mounted to the rear wall with velcro. OM2060 Model MMV Rev. 10/11...
  • Page 194 (4) on the front of the air storage tank. Push the outside of the quick disconnect back toward the tank, insert the male end into the quick disconnect and release the outside of the quick discon- nect to secure the air hose in the disconnect. OM2080 Model MMV Rev. 10/11...
  • Page 195 12. Remove the tire inflation hose from the quick disconnect and coil and remount the hose (6) on the rear wall of the cab, behind the seat (7). 13. Reassemble the dust cap (3) back onto the quick disconnect. OM2060 Model MMV Rev. 10/11...

  • Page 196: Batteries

    3. Wearing safety glasses, visually inspect the batteries for cleanli- ness. Check terminals for corrosion. Check the cable connections to ensure proper tightness. Replace a battery if it has a cracked, melted or damaged case. OM2200 Model MMV Rev. 10/11...
  • Page 197 See “Slave Starting” instructions on page 70. Extended Storage (S/N MV1210 & After) Move battery shut-off switch in the engine compartment to the "OFF" position if the machine will be in extended storage. Model MMV Rev. 10/11...

  • Page 198: Fuse & Relay Replacement

    Remove the plastic cover (3) from the fuse and relay block. When reassembling the cover plate to the side console, tighten the “T” knob thumb screws securely. OM2110 Model MMV Rev. 10/11...
  • Page 199 General Maintenance MU33801 Volt Circuit Controlled 12 Volt Transmission Control 12 Volt Ignition 12 Volt Neutral Start – Open – Open 12 Volt Stability Lock 12 Volt Boom Proximity – Open 12 Volt Cab Power – Open Model MMV Rev. 10/11...
  • Page 200 General Maintenance MU33901 Model MMV Rev. 10/11...
  • Page 201 7.5 Amp Brown Roof Wiper 7.5 Amp Brown Rear Wiper – – Open – – Open – – Open – – Open – – Open – – Open – – Open – – Open – – Open Model MMV Rev. 10/11...
  • Page 202 12 Volt – Relay - Brake Light 12 Volt – Relay - Light Power 12 Volt – Relay - Blackout Ignition 12 Volt – Relay - Normal Lights Ignition 12 Volt – Relay - Reverse Signal Model MMV Rev. 10/11...
  • Page 203 (17). Torque the hex nuts to 7-9 lb-ft (10-12 Nm). 5. Snap the protective cover back in place. Be sure the cover snaps securely in place on the holder. 6. Close and latch the engine cover when complete. OM2130 Model MMV Rev. 10/11...
  • Page 204 4. Reassemble the plastic cover onto the fuse holder and securely snap the cover in place. Replace any tie wraps that were removed, securing the fuse holders to the wire harness. 5. Close and latch the engine cover. OM2150 Model MMV Rev. 10/11...
  • Page 205 6. Secure in place with a flat washer (10), lockwasher (11) and hex nut (12). Torque the hex nut to a maximum of 100 lbs-in (11 Nm). OM3660 Model MMV Rev. 10/11...
  • Page 206 Unlatch and open the rear door. The relay is mounted to the fan shroud. Remove the protective cover (4) from the fuse holder (5) to gain access to the 15 amp (Blue) fuse. OM1660 Model MMV Rev. 10/11...

  • Page 207: Boom Chains And Wear Pads

    Acceptable boom chain sag is between 1.5" (38 mm) and 2.5" (64 mm). If the measurement is less than 1.5" (38 mm) or more than 2.5" (64 mm), the boom chains need to be adjusted. OA0491 Model MMV Rev. 10/11...
  • Page 208 8.5" (216 mm) to 9" (229 mm). NOTE: If the measurement is less than 8.5" (216 mm) the boom may require extensive adjustment and/or repair. Contact your local JLG Autho- rized Service Center (ASC). OT0760 Model MMV Rev. 10/11...
  • Page 209 10. Start the vehicle, cycle the boom in and out several times. With the boom horizontal, fully extend the boom and then retract it 2" (51 mm) (one inch per section). Turn the vehicle OFF. Model MMV Rev. 10/11...
  • Page 210 (3) is between 1.5" (38 mm) and 2.5" (64 mm). If the measure- ment is less than 1.5" (38 mm), the top boom extend chains need to be adjusted. See “Top Boom Chain Tension Adjustment” on page 207. OA0491 Model MMV Rev. 10/11...
  • Page 211 2. Adjust the top extend boom chains by tightening the locknuts (4) located at the rear of the boom (5). Be sure each locknut is tight- ened equally so that each chain maintains the same tension. OT0501 Model MMV Rev. 10/11...
  • Page 212 NOTE: If the top boom extend chain sag cannot be adjusted within the acceptable range of 1.5" (38 mm) to 2.5" (64 mm), the boom may require extensive adjustment and/or repair. Contact your local JLG Authorized Ser- vice Center (ASC). 6. Close and latch the rear door. Model MMV Rev. 10/11...
  • Page 213 (pins and plates), with a corresponding reduction in chain strength. Due to the inaccessibility of the bearing surfaces (pin surfaces and plate apertures), wear and scoring are not readily noticeable to the naked eye. Model MMV Rev. 10/11...
  • Page 214 3. Inspect the retract chain every 1000 hours of operation. Refer to the Service Manual for proper procedure. 4. Inspect the chains for the following conditions: Model MMV Rev. 10/11...
  • Page 215 The new chain link measures .713" (18 mm) (1). If the measurement of the worn chain is less than .677" (17 mm) (2), the chain should be replaced. MM2051 Model MMV Rev. 10/11...
  • Page 216 Refer to the Service Manual for inspection of the retract chain. The maximum measurement allowed is 12.36" (313 mm). If the measurement is more than 12.36" (313 mm), the chain should be replaced. MM2120 Model MMV Rev. 10/11...
  • Page 217 This condition damages the chain as well as increases frictional loading and should be corrected. MM2060 Distorted or Battered Link Plates Distorted or battered link plates (6) on a leaf chain cause tight joints and prevent flexing. MA9340 Model MMV Rev. 10/11...
  • Page 218 If the problem is caused by MM2110 dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re-installing the chain. If the problem is caused by corrosion and rust or bent pins, replace the chain. Model MMV Rev. 10/11...
  • Page 219 Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration. It is important that a reputable lubrication specialist, an JLG Authorized Service Center (ASC) or the vehicle distributor be consulted for guidance. Model MMV Rev. 10/11...
  • Page 220 Consequently, the lower pads at the front and the upper pads at the rear will require service more often. Model MMV Rev. 10/11...
  • Page 221 Light lubricating of the boom wear surfaces is also recommended in salt air climates, after cleaning with pressure washer using solvents or when the vehicle is to be put in storage, to prevent rusting. Model MMV Rev. 10/11...

  • Page 222: Storage And Transport

    11. Preferably, store the vehicle inside where it will remain dry. If it must be stored outside, park it on lumber laid on flat level ground or on a concrete slab and cover with a tarp. Model MMV Rev. 10/11...
  • Page 223 7. Refer to “Maintenance Schedule and Check List” on page 138. Per- form all the maintenance checks listed under the 10 Hour Intervals. 8. Review and familiarize yourself and any other operator with all the safe and proper operating procedures contained in this manual. Model MMV Rev. 10/11...

  • Page 224: Long Term Storage

    NOTE: Overspray will not harm paint, rubber and glass and will be easily removed. 10. Apply Teflon based lubricant to the fork shafts and the fork slide plates. Model MMV Rev. 10/11...
  • Page 225 1. To remove the transit coating, refer to the following steps. a. Wear the recommended safety equip- ment, rubber gloves and eye protection. OM1410 b. Assemble the transit coating decoater gun. OM1420 Model MMV Rev. 10/11...
  • Page 226 Refer to “Change Fuel Filter” on page 158 for procedure. 9. Review and familiarize yourself and any other operator with all the safe and proper operating procedures contained in this manual. Model MMV Rev. 10/11...

  • Page 227: Counterweight Removal And Reassembly

    The counterweight will require removal for certain transport applications. When removing the counterweight, another piece of equipment (such as another MMV) capable of lifting 5,000 lbs (2.268 kg) will be required. 1. Park the vehicle on level ground, frame sway the vehicle to 0° and ground the attachment.
  • Page 228 NOTE: When securing the counterweight (2) to the pallet (3), be sure to secure the counterweight insert (4). The counterweight insert is located in a “pocket” inside the counterweight. The insert weighs 500 lbs (227 kg). OM1160 Model MMV Rev. 10/11...
  • Page 229 5. Assemble the flat washers (6) onto the capscrews (5) and insert the capscrews with flat washers into the mounting holes in each side of the counterweight. Thread the capscrews into the threaded bush- ings (1) in the frame. Torque all capscrews to 680 lb-ft (922 Nm). Model MMV Rev. 10/11...

  • Page 230: Transport

    15.5" TIEDOWN C (394 mm) 74.8" (1900 mm) 55.3" (1405 mm) 14.4" DISTANCE 30.5" TIEDOWN A 47.3" (1201 mm) (366 mm) (775 mm) 131.0" 41.5" 41.0" (1041 mm) (3327 mm) (1054 mm) 33.0" (838 mm) OM1152 Model MMV Rev. 10/11...
  • Page 231 • Air Transport, C-130 Configuration. Refer to “Air Transport, C- 130 Configuration” on page 232. • Marine Transportability. Refer to “Marine Transportability” on page 234. • External Transport/Slinging. Refer to “External Transport/ Slinging” on page 235. Model MMV Rev. 10/11...
  • Page 232 Truck Transportability Refer to the following diagram. MIRROR TO BE ROTATED INWARD MIRROR TO BE ROTATED INWARD 93.6" (2377 mm) MAX HEIGHT 100.2" (2545 mm) MAX WIDTH STANDARD 96" COMMERCIAL 54" (1372 mm) TRAILER SHOWN OM1251 Model MMV Rev. 10/11...
  • Page 233 General Maintenance Rail Transportability and GIC Clearance Refer to the following diagram. NORTH AMERICAN NATO GIC RAIL TRANSPORT EQUIPMENT GAUGE GAUGE MIRROR TO BE ROTATED INWARD TIRE PROTECTIVE MATERIAL APPROX. 45° 50" (1270 mm) OM1261 Model MMV Rev. 10/11...
  • Page 234 Air Transport, C-17, C141 or C-5 Tiedowns Refer to the following diagrams. 111" (2819 mm) 103" (2616 mm) 103" (2616 mm) FS 734, 958, 998 & 1058 AFT OPENING DESIGN LIMITS 103" (2616 mm) 111.25" (2826 mm) MAXIMUM OM1280 TYPICAL SECTION Model MMV Rev. 10/11...
  • Page 235 Rear Front 15,700 lbs. 14,800 lbs. Axle Load (7.121 Kg) (6.713 Kg) 7,850 lbs. 7,400 lbs. Load/Tire (3.561 Kg) (3.357 Kg) 123 Sq. In. 119 Sq. In. Footprint Area @ 87 PSI (793 cm (768 cm Model MMV Rev. 10/11...
  • Page 236 MAXIMUM VIEW LOOKING REARWARD THROUGH AIRCRAFT LASH COUNTERWEIGHT, COUNTERWEIGHT INSERT AND CARRIAGE SECURELY. 12 13 18 19 24 25 FS245 CARGO ENVELOPE HEIGHT ENVELOPE OM1291 For axle weights and pallet weights refer to the following tables. Model MMV Rev. 10/11...
  • Page 237 290 lbs. 463L Pallet Weight (131 Kg) 2,500 lbs. 7,000 lb Fork Carriage Weight (1.134 Kg) 4,200 lbs. Counterweight Assembly Weight (1.905 Kg) 500 lbs. Counterweight Insert Weight (227 Kg) 7,490 lbs. Total Weight (3.397 Kg) Model MMV Rev. 10/11...
  • Page 238 General Maintenance Marine Transportability Refer to the following diagram. APPROX. 45° OM1331 Model MMV Rev. 10/11...
  • Page 239 (13.835 Kg) Not Allowed (7 K) 73.25" 29,300 lbs CH-53 5.0° 48" Load Center Carriage (1.860 mm) (13.290 Kg) Not Allowed (11 K) 78.75" 28,100 lbs CH-53 7.0° 24" Load Center Carriage (2.000 mm) (12.746 Kg) Approved Model MMV Rev. 10/11...

  • Page 240: Stabil-Trak™ System Test

    If the Stabil-TRAK Lock light goes OFF and the front left tire lowers to the ground consistently during Steps 4 through 7, the Stabil-TRAK system is not functioning properly and the test should be stopped immediately. Contact your local JLG Authorized Service Center (ASC) immediately to repair the system. Model MMV Rev. 10/11...
  • Page 241 Move the travel select lever to the (N) NEUTRAL position. c. Raise the boom to exactly 60°. The Stabil-TRAK Lock light should come ON when the boom angle is at about 40° and remain ON. The Stabil-TRAK Slow Pivot light should be OFF. Model MMV Rev. 10/11...
  • Page 242 With the travel select lever in the (N) NEUTRAL position, engage the parking brake switch. b. Move the travel select lever to the (F) FORWARD position. The Stabil-TRAK Lock light should remain ON and the front left tire should remain off the ground. Model MMV Rev. 10/11...
  • Page 243 The Stabil-TRAK Lock light should go OFF and the Stabil- TRAK Slow Pivot light should come ON. f. The front left tire should return to the ground while the vehicle travels in reverse. g. Depress the service brake pedal to stop the vehicle. Model MMV Rev. 10/11...
  • Page 244 If any of these steps indicate that the Stabil-TRAK system is not functioning properly, contact your local JLG Authorized Service Center (ASC) immediately to repair the system. Model MMV Rev. 10/11...
  • Page 245 Test 2 - Transmission De-Clutch/Parking Brake Activation a. With the vehicle unloaded, disengage the parking brake. b. Move the travel select lever to (F) FORWARD. c. Move the unit slowly in a forward direction (approximately 1 mph [1,6 km/h]). Model MMV Rev. 10/11...
  • Page 246 Test Procedures d. Engage the parking brake. The unit should stop abruptly. Model MMV Rev. 10/11...
  • Page 247 3. Place the accident prevention tags (1) on the ignition switch (2) and the steering wheel (3). 4. Service the parking brake immediately or contact your local JLG Authorized Service Center (ASC) to repair the system. DANGER OM1750 Model MMV Rev. 10/11...

  • Page 248: Four Wheel Steer Indexing Procedure

    11. Drive the vehicle forward a short distance to check the wheel track- ing. The vehicle should now be properly indexed in Four Wheel Steering. If the wheels are still out-of-phase, repeat the above procedure. OM2030 Model MMV Rev. 10/11...

  • Page 249: Fluid & Lubrication Capacities

    Reservoir Capacity to Full Mark......28.5 gallons (108 liters) Type of Oil.............See Chart On page 164 14° F (-10° C) & Above..MIL-PRF-2104G Grade 10 Hydraulic Oil 125° F (50° C) & Below . DEXRON lll (Automatic Transmission Fluid) Model MMV Rev. 10/11...
  • Page 250 (Universal Tractor Fluid) Carraro Transfer Case Capacity ..............1.5 quarts (1,4 liters) Type of Oil ............See Chart On page 184 0° F to 104° F (-20° C to 40° C) ..MIL-I-2105GL-5 Grade 80W90 with EP Properties Model MMV Rev. 10/11...

  • Page 251: Tires

    11K Fork carriage (15.5R25, L-2, 2 star) ....280 sq. in. (1.806 cm With 45 psi (310 kPa) Tire Pressure: 7K Fork carriage (15.5R25, L-2, 2 star) ....170 sq. in. (1.097 cm 11K Fork carriage (15.5R25, L-2, 2 star) ....170 sq. in. (1.097 cm Model MMV Rev. 10/11...

  • Page 252: Weights

    Curb Weight (with 11K fork carriage)......28,100 lbs (12.746 Kg) Curb Weight (without any carriages) ......26,900 lbs (12.202 Kg) Maximum Rated Capacity: 7K Fork Carriage ............7,000 lbs (3.175 Kg) 11K Fork Carriage ............ 11,000 lbs (4.989 Kg) Model MMV Rev. 10/11...

  • Page 253: Vehicle Dimensions

    (D) Wheelbase ............131 inches (3.327 mm) (E) Ground Clearance..........15.1 inches (383 mm) (F) Tread Center ............84 inches (2.134 mm) (G) Maximum Lift Height ......42 feet 4 inches (12,9 meters) (H) Max. Forward Reach..........30 feet (9,1 meters) OM2040 Model MMV Rev. 10/11...

  • Page 254: Electrical System

    Fork Side Shift - Right ..............7.5 Amp LMI (Load Moment Indicator) ............3 Amp ECM Indicator Light................3 Amp Closed Cab - Main................40 Amp Front Wiper..................10 Amp Heater Fan ..................25 Amp Roof Wiper ..................7.5 Amp Rear Wiper ..................7.5 Amp Model MMV Rev. 10/11...
  • Page 255 ECM Fuses (Qty 3) ............... 10 Amp Cold Start Grid Heater Fuse (Qty 1) ........... 125 Amp Fuse & Relay Ratings (Inside Rear Door): Air Conditioner Condenser Fan Motor ........... 15 Amp Air Conditioner Condenser Fan Relay ..........12 Volt Model MMV Rev. 10/11...

  • Page 256: Engine

    Specifications Engine Turbocharged Cummins: Model................... QSB4.5T Horsepower ..............110 hp @ 2500 rpm Model MMV Rev. 10/11...
  • Page 257 Specifications This Page Intentionally Left Blank Model MMV Rev. 10/11...
  • Page 258 Specifications Model MMV Rev. 10/11...

  • Page 259: Index

    Boom Chain Tension Check ..203 Elevating Personnel ....16, 107 Boom Extend Letters ......93 Emergency Boom Lowering ..123 Brake Disk Inspection ....175 Emergency Exit ......17 Brake Pedal ........23 Emergency Tire Inflation System ........188 Model MMV Rev. 10/11...
  • Page 260 Tables ........94 Fuses ........... 194 Load Moment Indicator ....63 Locked Mode ........74 Long Term Storage ......220 Gauges and Indicators ....59 Low Brake Pressure Warning Gear Select Lever ......30 Indicator ........58 GIC Clearance ......229 Model MMV Rev. 10/11...
  • Page 261 Rear Window Latch ......46 Transfer Case Oil Rear Window Washer ....49 Carraro ........184 Rear Window Wiper .......49 ZF ..........182 Recirculation Air Filter ....147 Transfer Case Oil Change Refueling ........71 Carraro ........185 Relays ..........194 ZF ..........183 Model MMV Rev. 10/11...
  • Page 262 Visual Obstruction ......14 Warning Indicator Lights ....57 Warranty Registration ...... 2 Wear Pad Inspection ....216 Wear Pad Replacement ....217 Wheel End Oil ......179 Wheel End Oil Change ....180 Worklights ........41 Model MMV Rev. 10/11...
  • Page 263 TRANSFER OF OWNERSHIP An Oshkosh Corporation Company To Product Owner: If you now own but ARE NOT the original purchaser of the product covered by this manual, we would like to know who you are. For the purpose of receiving safety-related bulletins, it is very important to keep JLG Industries, Inc.
  • Page 265 Accident Prevention Tags Accident Prevention Tags 8990401 Origin 5/00 OS2180...
  • Page 266 Accident Prevention Tags 8990401 Origin 5/00 OS2180...
  • Page 267 Replacement Manuals If the owner/operator or safety manuals that were originally shipped with your vehicle are lost, stolen or need replacement, contact your local distributor for replacement manuals. If for any reason your distributor cannot supply the manuals you need; write, call or send a fax to the following address for ordering information.
  • Page 268 8990504 An Oshkosh Corporation Company JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd P.O. Box 5119 Rua Antonia Martins Luiz, 580 Bentley House 11 Bolwarra Road...

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