Skyjack ZB12032 Operating Manual
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Skyjack ZB12032 Operating Manual

Skyjack ZB12032 Operating Manual

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MODELS
ZB12032
Operating Manual
ZOOM BOOM Telehandlers
Part No. 402286AB-A
September 2010

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Summary of Contents for Skyjack ZB12032

  • Page 1 MODELS ZB12032 Operating Manual ZOOM BOOM Telehandlers Part No. 402286AB-A September 2010...
  • Page 2 Skyjack Service Center 3451 Swenson Ave. St. Charles, Illinois, 60174 USA Phone: 630-262-0005 Toll Free: 1-800-275-9522 Fax: 630-262-0006 Email: service@skyjack.com Parts (North America) Toll Free: 1-800-965-4626 Toll Free Fax: 1-888-782-4825 Email: parts@skyjack.com Parts & Service (Europe) Unit 1 Maes Y Clawdd, Maesbury Road Industrial Estate...
  • Page 3 It may also be used to alert against unsafe practices. impORTANT IMPORTANT indicates a procedure essential for safe operation and which, if not followed, may result in a malfunction or damage to the telehandler. ZB12032 December 2007 Page 3...

  • Page 4: Table Of Contents

    Safety Switches ..........................27 2.7-4 Mirrors ..............................27 2.7-5 Hydraulic ............................28 2.7-6 Cylinders ............................28 2.7-7 Frame ...............................28 2.7-8 Engine Compartment ........................30 2.7-9 Boom ...............................31 2.7-10 Transmission ............................32 2.7-11 Lifting Attachment ..........................32 2.7-12 Grease Points ..........................32 2.7-13 Operator’s Cab ..........................34 ZB12032 Page 4 December 2007...
  • Page 5 Towing the Telehandler ........................55 2.14 Tables................................56 2.15 Labels ................................62 List of Tables Standard and Optional Equipment .........................56 Specifications and Dimensions ........................57 Tire/Wheel Specifications ..........................58 Recommended Fluids/Lubrication ........................59 Maintenance and Inspection Schedule ......................60 Operator’s Checklist ............................61 ZB12032 December 2007 Page 5...
  • Page 6 Notes ZB12032 Page 6 December 2007...

  • Page 7: Telehandler Definition

    Service Policy and Warranty SKYJACK warrants each new ZB series telehandler to be free of defective parts and workmanship for the first 12 months or 2000 hours, whichever occurs first. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or labor.

  • Page 8: Safety Rules

    Some attachments may not be approved for use with certain telehandler models. Use only approved attachments. Any modifications from the original design are strictly forbidden without written permission from Skyjack. ZB12032 Page 8...

  • Page 9: Electrocution Hazard

    Always assume electrical power sources and overhead lines are energized. DO NOT USE TELEHANDLER AS A GROUND FOR WELDING. DO NOT OPERATE TELEHANDLER DURING LIGHTNING OR STORMS. ZB12032 December 2007 Page 9...

  • Page 10: Safety Precautions

    • ENSURE that there are no personnel or obstructions in the path of travel, • DO NOT climb on this including blind spots. vehicle for any reason. • AwARE blind spots when operating the telehandler. ZB12032 Page 10 December 2007...
  • Page 11 • operate on • DO NOT drive with boom surfaces not capable of elevated. holding the weight of the telehandler; including the rated load (e.g., covers, drains, and trenches). ZB12032 December 2007 Page 11...
  • Page 12 • KEEp forks close to the ground when in motion to increase telehandler stability decrease • frame potential injury leveling when boom is others. When fully elevated. stopped, lower forks completely to the ground. ZB12032 Page 12 December 2007...
  • Page 13 • wALK AROUND telehandler before operation check for any visible signs of damage or malfunction. • AwARE obstructions while traveling. • CHECK lights for proper function before operating. ZB12032 December 2007 Page 13...
  • Page 14 THE OpERATOR’S CAB provides a falling object protection structure (FOPS) and a rollover protection structure (ROPS). Do not make any modification to this structure. If damaged, the cab cannot be repaired. It must be replaced. ZB12032 Page 14 December 2007...
  • Page 15 • has been tagged or locked out for non-use or repair. • bears an unapproved attachment. Failure to avoid these hazards could result in death or serious injury. ZB12032 December 2007 Page 15...
  • Page 16 Notes ZB12032 Page 16 December 2007...

  • Page 17: Section 2 - Operation

    2.1-4 Owner’s Inspections It is the responsibility of the owner and/or operator to arrange daily, quarterly (or 250 hours) and annual inspections of the telehandler. Refer to Table 2.5 recommended maintenance and inspection areas and intervals. ZB12032 December 2007 Page 17...

  • Page 18: Major Components

    Section 2 - Operation 2.2 Major Components Attachment Tilt Boom Assembly Cylinder Boom Lift Cylinder Pipe-Grappler Attachment Frame Rear Axle Front Axle and Tire and Tire Operator’s Cab ZB12032 ZB12032 Telehandler Telehandler ZB12032 Page 18 December 2007...

  • Page 19: Major Assemblies

    The boom is mounted on the frame and consists of two telescoping boom sections. 2.3-4 Attachment The attachment is a material-handling device attached to the boom. The standard attachment is a fork carriage. Refer to Section 2.12 for various attachments. ZB12032 December 2007 Page 19...

  • Page 20: Component Identification

    The telehandler seat is equipped with devices which allow for the adjustment of seat height and distance from the controls. Adjust the seat so that foot pedals, steering wheel and instrument panel controls are within easy reach of the operator. ZB12032 Page 20 December 2007...

  • Page 21: Operator's Cab Controls

    Steering Wheel - Turn the steering wheel to the left or right to steer the telehandler in the corresponding direction. Three steering modes are available (refer to Section 2.9-4). Heater Fan Switch (If Equipped) - This switch selects fan speed. ZB12032 December 2007 Page 21...
  • Page 22 To close secondary clamp, press and hold right- reverse movement of transmission lever. side switch while pushing joystick forward. Capacity Charts - This set of charts indicates operating limits specific to a telehandler model and attachments. Refer to Section 2.11 ZB12032 Page 22 December 2007...
  • Page 23 NOTE brake. Turn on both signals switches to use as emergency flashers. Select rocker switch backward “ ” position when operating on a slope. While in this position, the transmission will remain in gear. ZB12032 December 2007 Page 23...
  • Page 24 Axle Lock Light - This light indicates frame leveling is locked in position. Low Brake Pressure Light - This light illuminates when brake pressure is low. Park telehandler safely and have it serviced. ZB12032 Page 24 December 2007...

  • Page 25: Operator's Responsibility

    (see • Designed to discover any malfunctions before the Table 2.5). telehandler is put into service. impORTANT The operator must understand and follow the step-by-step instructions to test all telehandler functions. ZB12032 Page 26 December 2007...

  • Page 26: Visual And Daily Maintenance Inspections

    2.7-1 Labels Refer to the labels section in this manual and determine that all labels are in place and are legible. ZB12032 December 2007 Page 27...

  • Page 27: Hydraulic

    An over-inflated tire can explode and parts, steer linkage studs are locked and may cause death or serious injury. there is no visible damage. Check all tire treads and sidewalls for cuts, cracks, punctures and unusual wear. ZB12032 Page 28 December 2007...
  • Page 28 3. Ensure all battery connections are tight. 4. If applicable, check battery fluid level. If plates are not covered by at least 1/2” (13 mm) of solution, add distilled or demineralized water. ZB12032 December 2007 Page 29...

  • Page 29: Engine Compartment

    Refer to service manual DANGER for proper replacement procedure. Engine fuels are combustible. Inspect the telehandler in an open, well-ventilated area away from heaters, sparks and flames. Always have an approved fire extinguisher within easy reach. ZB12032 Page 30 December 2007...

  • Page 30: Boom

    Ensure all bolts are tight, and there is no the minimum and maximum marks on the visible damage sight glass. Add oil as needed. • Hydraulic Return Filter Ensure filter element is secure. Ensure there are no signs of leakage or visible damage. ZB12032 December 2007 Page 31...

  • Page 31: 10 Transmission

    Ensure that there are no personnel or obstructions in maintenance area. Greasing intervals are based on telehandler usage of 40 hours. Use of telehandler may vary significantly and greasing frequency must be adjusted to obtain maximum service life. ZB12032 Page 32 December 2007...
  • Page 32 3. Using a creeper, slide under the frame to attachment pivot bearings locate grease fittings and pump grease in the following: drive shaft U-joint (front and rear) slip joint on drive shaft (front and rear) ZB12032 December 2007 Page 33...

  • Page 33: 13 Operator's Cab

    Ensure a copy of operating manual, DANGER and other important documentation are enclosed in manual storage box. Do not operate the telehandler if capacity charts are missing or not legible. Ensure manual is legible and in good condition. ZB12032 Page 34 December 2007...

  • Page 34: Function Tests

    Ensure parking brake is engaged. understand Section 2.9 - Start Operation. Adjust the boom controller console. wARNiNG Ensure there are no personnel or obstructions in test area and there is sufficient room to test all telehandler functions. ZB12032 December 2007 Page 35...
  • Page 35 Result: The indicator light and right signal 2. Depress service brake pedal and shift the lights should flash. transmission lever backward. Result: The reverse alarm should sound and reverse light (if equipped) should turn ZB12032 Page 36 December 2007...
  • Page 36 7. Shift transmission lever backward and is stationary. release the service brake pedal slowly. Result: Telehandler should move backward. 8. Depress service brake pedal slowly. Result: Telehandler should stop. 9. Return transmission lever to neutral position and engage parking brake. ZB12032 December 2007 Page 37...
  • Page 37 5. Turn the steering wheel to the left or right should turn in the chosen direction. and drive forward. Result: Telehandler should move in the chosen direction, producing a turning circle, with front wheels pointing in the opposite direction to the rear wheels. ZB12032 Page 38 December 2007...
  • Page 38 14. Steer the telehandler straight ahead until all four wheels are aligned. 15. Depress service brake pedal until the telehandler stops. Figure 2-4 Crab Steering 12. Select rocker switch to backward “ ” position for crab steering. ZB12032 December 2007 Page 39...
  • Page 39 4. Depress service brake pedal slowly until telehandler stops. 5. Select parking brake rocker switch to on position and release service brake pedal. Result: Parking brake indicator light should turn on and telehandler should not roll ZB12032 Page 40 December 2007...
  • Page 40 3. Extend boom by moving boom/attachment joystick to the right. 8. Raise the boom until attachment is 2 feet Result: Boom should extend and boom above the ground (refer to Section 2.12 extension indicators are visible. for attachments). ZB12032 December 2007 Page 41...
  • Page 41 R e s u l t : T h e e n g i n e R P M s h o u l d increase. 3. Release the accelerator pedal. R e s u l t : T h e e n g i n e R P M s h o u l d decrease. ZB12032 Page 42 December 2007...

  • Page 42: Start Operation

    • has safety devices which have been altered or disabled. • has been tagged or locked out for non-use or repair. Failure to avoid these hazards could result in death or serious injury. ZB12032 Page 44 December 2007...

  • Page 43: Driving The Telehandler

    Select higher gears only when traveling long distances on smooth terrain without a load. Always bring the telehandler to a complete stop before changing the direction of travel. Figure 2-5 Driving on Slopes ZB12032 December 2007 Page 45...

  • Page 44: Steering The Telehandler

    To raise the boom, pull boom/attachment joystick backward. To lower the boom, push boom/ attachment joystick forward. Release joystick to stop. Figure 2-7 Front Steering ZB12032 Page 46 December 2007...

  • Page 45: Extending Or Retracting Primary The Boom

    Level the frame before lifting the load. Use outriggers (if equipped) for maximum stability. Use attachment to pickup/place the load. Refer to procedure Section 2.12 for specific attachment uses. Retract and keep the attachment/load as low as practical. ZB12032 December 2007 Page 47...

  • Page 46: Parking And Shutting-Down The Telehandler

    Position telehandler on a firm and level surface. wARNiNG Always engage parking brake before leaving the cab. Engage parking brake. Move transmission shift lever to neutral position. Ensure transmission gear selector is in first gear position. ZB12032 Page 48 December 2007...

  • Page 47: Refueling Procedure (Diesel Fuel Only)

    Never try to start telehandler if you smell diesel. wARNiNG D o n o t s m o k e i n a n a r e a w h e r e telehandlers are stored or refueled. ZB12032 December 2007 Page 49...

  • Page 48: Use Of The Capacity Chart

    Section 2 - Operation Procedures Capacity Chart CAPACITY CHART MODEL ZB12032 HEIGHT Telehandler THIS CHART COVERS PIPE GRAPPLER ATTACHMENT Height RATED CAPACITY AT 24" Model LOAD CENTRE 72° (9.8) 60° Telehandler LOAD RATINGS COMPLY (8.5) WITH ANSI/ITSDF B56.6- Attachment 2005 STABILITY 50°...

  • Page 49: Examples On Reading The Capacity Chart

    7400 lb. (3357 kg) 13 ft. (4.0 m) 7 ft. (2.1 m) 10° 5000 lb. (2268 kg) SAMPLE ONLY - USE CHART IN CAB CAPACITY CHART MODEL ZB12032 HEIGHT THIS CHART COVERS PIPE GRAPPLER ATTACHMENT RATED CAPACITY AT 24" LOAD CENTRE 72°...

  • Page 50: Pipe Grappler Attachment Operation

    Approach load slowly with grappler perpendicular Return boom to transport position. to the load and both primary and secondary clamps open. Insert forks under center of the load and raise it 5 to 10 inches. ZB12032 Page 52 December 2007...

  • Page 51: Loading And Transporting

    Ensure telehandler is level prior to loading. wARNiNG Fully lower and retract boom and raise outriggers Inspect telehandler for loose or unsecured (if equipped). items. Ensure ramps are correctly positioned. Figure 2-13 Tie-down points ZB12032 Page 54 December 2007...

  • Page 52: Towing The Telehandler

    Grades can require additional distance to stop the telehandler. Be careful if traction conditions are bad or the machine on an incline. Fig 2-14 Towing the telehandler from front tie-down points ZB12032 December 2007 Page 55...

  • Page 53: Standard And Optional Equipment

    Section 2 - Operation Tables Table 2.1 Standard and Optional Equipment MODEL ZB12032 S T A N D A R D E Q U I P M E N T Pilot-operated joystick boom & frame level controls 4-wheel power steering...

  • Page 54: Tables

    Tables Section 2 - Operation Table 2.2 Specifications and Dimensions MODEL ZB12032 Engine Type Cummins QSB4.5C110T3 Max RPM 2500 rpm Horsepower @ 2300 RPM 115 HP Horsepower @ 2500 RPM 110 HP Fuel type Diesel Transmission Type T20000 Speeds forward...

  • Page 55: Tire/Wheel Specifications

    Intermixing tires of different types or using tires of types other than those originally supplied with this equipment can adversely affect stability. Therefore, replace tires only with the exact original Skyjack-approved type. Failure to operate with matched approved tires in good condition may result in death or serious injury.

  • Page 56: Recommended Fluids/Lubrication

    Friction modifier FM7099 per axle Planetary Wheel Ends SAE 80W-90 GL 5 Type Anti-wear ISO Gr. 32 Tank Capacity 41 gal (155 L) Boom Slide Bearings Sunaplex 992 E.P. 2 General Greasing Multi Purpose E.P. 274A ZB12032 December 2007 Page 59...

  • Page 57: Labels

    C - Perform Scheduled Maintenance Inspection. Refer to Service manual. * - Maintenance must be performed only by trained and competent personnel who are familiar with mechanical procedures. † - Refer to Skyjack's website @ www.skyjack.com for latest service bulletins prior to performing quarterly or yearly inspection.

  • Page 58: Operator's Checklist

    Model: Hourmeter Reading: Operator's Name (Printed): Date: Time: Operator's Signature: Each item shall be inspected using the appropriate section of the Skyjack operating manual. As each item is inspected, check the appropriate box. - PASS DAILY - FAIL FREQUENTLY - REPAIRED...
  • Page 59 SECURED FROM SLIDING. DEC-078 Boom Extension Indicate the extension of the boom. Grease GREASE GREASE Grease point DEC-005R ZoomBoom Zoom Boom logo Model Number* 12032 Product Identifier *Model number will vary, may not be as shown. ZB12032 Page 62 December 2007...
  • Page 60 Label Pictorial Description Model Number* 12032 Product Identifier *Model number will vary, may not be as shown. Grease Inside GREASE Grease points INSIDE DEC-101 Skyjack Logo Small Skyjack logo - black Grease GREASE Grease point DEC-005L ZB12032 December 2007 Page 63...
  • Page 61 SEQUENCE 50-100 450-500 FT-LBS. FT-LBS. DEC-304 Label Pictorial Description Skyjack Logo Skyjack logo - black Turbo Turbo Telehandler is equipped with a turbo engine. Canada & U.S.A. Flags North American made - North American tough Oil Type Label TRANSMISSION DIPSTICK...
  • Page 62 Indicates torque sequence and torque values 50-100 450-500 FT-LBS. FT-LBS. DEC-304 Skyjack Logo Skyjack logo - black Turbo Turbo Telehandler is equipped with a turbo engine. Canada & U.S.A. Flags North American made - North American tough ZB12032 December 2007...
  • Page 63 TANK, NOT THE RADIATOR. CUMMINS ENGINEERING STANDARD (CES) 14603 ALWAYS USE DISTILLED OR DEIONIZED WATER  Warning! Not Elevating Device WARNING Do not use telehandler as a elevating device. DEC-016 Skyjack Logo Skyjack logo - black ZB12032 Page 66 December 2007...
  • Page 64 Diesel Fuel Only DIESEL FUEL ONLY Refill fuel tank with diesel fuel only. DEC-010 HYDRAULIC OIL Hydraulic Oil ALL WEATHER TYPE Refill Hydraulic oil tank with all weather type hydraulic oil. SEE OPERATORS SERVICE MANUAL DEC-009 ZB12032 December 2007 Page 67...
  • Page 65 WATCH FOR OVERHEAD LINES OR OTHER OBSTRUCTIONS DEC-024 Service Chart CHECK ENGINE OIL LEVEL ZB12032 CHECK AND CLEAN ENGINE AIR FILTERS CHECK ENGINE COOLANT LEVEL AT COOLANT RESERVOIR CHECK TIRE PRESSURE CHECK HYDRAULIC FLUID LEVEL...
  • Page 66 AUX Function Joystick    Auxiliary function joystick                  Frame Level FRAME Frame level left or right LEVEL DEC-055 ZB12032 December 2007 Page 69...
  • Page 67 Telehandler is equipped with a back-up alarm. ALARM MUST SOUND WHEN BACKING IT IS THE DRIVER'S RESPONSIBILTY TO OPERATE THIS VEHICLE SAFELY BE SURE BACKUP ALARM IS OPERATING DEC-109 No Riders Warning WARNING Absolutely no riders on telehandler. No Riders DEC-013A ZB12032 Page 70 December 2007...
  • Page 68 TO INITIALIZE, THEN START ENGINE. DEC-322 Horn HORN Horn label DEC-308E Transportation Reminder IMPORTANT ALL TURBO-ENGINES Ensure engine, air cleaner, and exhaust are sealed during AIR CLEANER AND EXHAUST MUST BE SEALED DURING TRANSPORT transportation. DEC-052 ZB12032 December 2007 Page 71...
  • Page 69 Notes ZB12032 Page 72 December 2007...
  • Page 70 Notes ZB12032 December 2007 Page 73...
  • Page 71 Notes ZB12032 Page 74 December 2007...
  • Page 72 California Proposition 65 WARNING Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals, and related accessories contain lead and lead com- pounds, chemicals known to the State of California to cause cancer, birth defects, and other reproductive harm.
  • Page 73 Reliable lift solutions by people who care. www.skyjack.com...

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