Skyjack ZB2044 Page 1 Operating Manual Download

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TELEHANDLERS

MODELS

ZB2044

213530ABA

July 2018

OPERATING MANUAL (ANSI/CSA)

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Summary of Contents for ZB2044

Page 1: ...TELEHANDLERS MODELS ZB2044 213530ABA July 2018 OPERATING MANUAL ANSI CSA T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 2: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 3: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 4: ...This manual is based on Serial Numbers ZB 2044 85 800 125 Above T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 5: ...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 tele...

Page 6: ...bly 19 2 3 4 Attachment 19 2 4 Serial Number Nameplate 19 2 5 Component Identification 20 2 5 1 Boom Angle Indicator 20 2 5 2 Operator s Cab 20 2 5 3 Operator s Cab Controls 21 2 6 Component Identific...

Page 7: ...riable Heights 54 2 14 3 Adjusting Forks 55 2 14 4 Changing Forks 55 2 14 5 Slinging Loads 55 2 15 Optional Attachments 56 2 15 1 Fork Positioner Attachment 56 2 15 2 Combination Fork Positioner Sides...

Page 8: ...ls found within this manual If any labels are damaged or missing replace them immediately Service Policy and Warranty SKYJACK warrants each new ZB series telehandler to be free of defective parts and...

Page 9: ...e the best insurance against an accident Therefore proper usage of this telehandler is mandatory The following pages of this manual should be read and understood completely before operating the teleha...

Page 10: ...payload should be brought closer to any energized overhead electrical conductor with nominal phase voltage rating as specified below Voltage Distance 750 to 150 000 10 feet 150 000 to 250 000 15 feet...

Page 11: ...te WEAR all the protective clothing and personal safety devices issued to you or called for by job conditions DO NOT wear loose clothing dangling neckties scarves rings wristwatches or other jewelry w...

Page 12: ...DO NOT enter the danger area under or around the boom when forks are off the ground or while engine is running DO NOT lower the boom unless the area below is clear of personnel and obstruction DO NOTe...

Page 13: ...ing vehicle Use provided hand holds and steps only ALWAYS wear your seat belt when operating this vehicle KNOW the weight of the load you are transporting Never lift more than the lifting capacity at...

Page 14: ...forks backwards slightly when traveling to decrease potential of load slipping off SECURE loose loads with chains or straps to decrease potential of spills or injury to others TETHER LOADS that may s...

Page 15: ...d and wheels aligned straight ahead ALWAYS look in the direction of travel Reduce speed and be careful especially when traveling in reverse and or turning Bring the telehandler to a complete stop befo...

Page 16: ...imes during entering and exiting WARNING Operator should not use any telehandler that does not appear to be working properly has been damaged or appears to have worn or missing parts has alterations o...

Page 17: ...roper authorization and training Failure to avoid this hazard could result in death or serious injury 2 1 2 Operator s Responsibility for Maintenance WARNING Maintenance must be performed by trained a...

Page 18: ...ndler Attachment Tilt Cylinders Boom Assembly Boom Angle Indicator Operator s Cab Boom Lift Cylinder Engine Air Intake Front Axle and Tire Rear Axle and Tire Rear Axle Lock Cylinder Outriggers Fork Ca...

Page 19: ...n Boom assembly also includes a subcarriage which is mounted to the yoke and is supported by two tilt cylinders 2 3 4 Attachment The attachment is a material handling device attached to the boom The s...

Page 20: ...losed cab The operator s seat is equipped with a seat belt Use this seat belt at all times when operating the telehandler Seat belt Height Adjustment Ride Control Adjustment Fore Aft Lock Lever Figure...

Page 21: ...the boom raise lower and extend retract functions The lever returns to neutral when released The thumb button on top of handle selects the attachment tilt function To raise the boom move joystick bac...

Page 22: ...of the controller box 11 Accelerator Pedal Depress pedal to increase speed and release pedal to decrease speed 12 Service Brake Pedal The service brake is foot operated and is used to decrease speed...

Page 23: ...ront steer and crab steer Refer to Section 2 10 4 for steering procedure 19 Parking Brake Switch This switch controls the application and release of parking brake 20 Secondary Park Brake Switch If Equ...

Page 24: ...d move the parameter selection to the right or downward 30 Enter Key Select a menu or parameter or hide view an active fault code 31 Fuel Gauge This gauge displays level of fuel in fuel tank 32 Transm...

Page 25: ...system to maintain steering control The telehandler should be brought to an immediate stop while steering control is still available Reserve Steering Accumulator One way Directional Valve Figure 2 4 R...

Page 26: ...in an unsafe operating condition 2 Function Tests Designed to discover any malfunctions before the telehandler is put into service IMPORTANT The operator must understand and follow the step by step in...

Page 27: ...ect all switches electrical and hydraulic components 2 8 1 Labels Refer to the labels section in this manual and determine that all labels are in place and are legible 2 8 2 Electrical Maintaining the...

Page 28: ...NING An over inflated tire can explode and may cause death or serious injury Check all tire treads and sidewalls for cuts cracks punctures and unusual wear Check each wheel for damage and cracked weld...

Page 29: ...all connections are tight 4 If applicable check battery fluid level If plates are not covered add distilled or demineralized water 5 Replace batteries if damaged or incapable of holding a lasting cha...

Page 30: ...ls 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 Perform a visual inspection a...

Page 31: ...n and then visually inspect the sight gauge located on the side of the hydraulic oil tank The hydraulic oil level should be between the minimum and maximum marks on the sight glass Add oil as needed R...

Page 32: ...tachment Ensure there are no loose or missing parts and there is no visible damage Ensure attachment is properly positioned and secured refer to Section 2 15 for attachments 2 8 12 Grease Points Maint...

Page 33: ...cylinders top and bottom 3 Using a creeper slide under the frame to locate grease fittings and pump grease in the following drive shaft U joint front and rear slip joint on drive shaft front and rear...

Page 34: ...s cab Ensure door and windows if equipped are secure and in proper working order Ensure steering wheel is secured with no sign of visible damage Ensure all switches and controls are properly secured w...

Page 35: ...belt must be worn at all times 2 Sit in the driver s seat and fasten seat belt 3 Using a spotter adjust the mirrors 4 Ensure parking brake is engaged 5 Adjust the boom controller console 6 Insert key...

Page 36: ...sition and switch guard is down Test Lights If Equipped 1 Use a spotter to check if all the lights are working well The spotter should maintain a safe distance from telehandler 2 Turn parking brake sw...

Page 37: ...hment joystick to the left Result Boom should retract 7 Lower the boom by moving the boom attachment joystick forward Result Boom should lower 8 Raise the boom until attachment is 2 feet above the gro...

Page 38: ...t The engine RPM should decrease 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...

Page 39: ...ler should stop 9 Return transmission lever to neutral position and engage parking brake Test Steering CAUTION Before changing steering modes bring all four wheels into alignment i e in the straight a...

Page 40: ...handler straight ahead until all four wheels are aligned 7 Depress service brake pedal until the telehandler stops Front Steer Figure 2 8 Front Steering 8 Select rocker switch to middle position for f...

Page 41: ...y Panel 10 Steer the telehandler straight ahead until all four wheels are aligned 11 Depress service brake pedal until the telehandler stops Crab Steer Figure 2 9 Crab Steering 12 Select rocker switch...

Page 42: ...or obstructions in test area and that there is sufficient room to test all telehandler functions 1 Ensure parking brake switch is on 2 Lower outriggers by depressing and holding rocker switch forward...

Page 43: ...ed motion is clear 2 Ensure both park and secondary park brake switches are off 3 Drive the telehandler on a slope 4 Depress service brake pedal slowly until telehandler stops 5 Select secondary brake...

Page 44: ...f unauthorized personnel other possible unsafe conditions WARNING An operator should not use any telehandler that does not appear to be working properly has been damaged or appears to have worn or mis...

Page 45: ...d grip to select higher gear until the desired speed is reached 5 Select appropriate gear for the task being performed Select lower gear when transporting load traveling through deep mud rough terrain...

Page 46: ...f electrical power will allow front steering only Figure 2 12 Front Steering Crab Steer The crab steer is used for maneuvering into tight spots Figure 2 13 Crab Steering 2 10 5 Leveling the Telehandle...

Page 47: ...on the load behind front face of the tires Never drive the telehandler with the boom raised Do not exceed telehandler lift capacity refer to capacity charts inside operator s cab Exceeding lift capaci...

Page 48: ...ntain three points of contact to mount dismount the cab 8 Dismount from telehandler 9 Chock or block tires to prevent telehandler from rolling 2 11 Refueling Procedure Diesel Fuel Only This section pr...

Page 49: ...icators and boom angle indicator remain within previously determined calculated capacity zone Capacity Chart Telehandler Model Telehandler Attachment Boom Extension NO LIFT ZONE FORWARD REACH LOAD RAT...

Page 50: ...500 lb 3 860 kg YES 6 14 450 lb 6 554 kg 7 ft 2 1 m 4 ft 1 2 m 0 B 15 000 6 800 kg YES FORWARD REACH WHEN FULLY RETRACTED LOAD RATINGS COMPLY WITH ANSI ITSDF B56 6 2005 STABILITY REQUIREMENTS FOR ROU...

Page 51: ...attachment on the ground and tilt subcarriage forward until subcarriage bar is clear of the hooks see Figure 2 17 2 7 Retract boom disengaging the attachment see Figure 2 17 1 2 13 2 Installing Attac...

Page 52: ...or the width of the load This increases the stability of the load and the lift 4 Approach load slowly with forks straight ahead and perpendicular to the load 5 Deploy outriggers and insert forks under...

Page 53: ...of the load and the lift 4 Approach load slowly raise and extend the boom until the forks are perpendicular to the load 5 Deploy outriggers for maximum stability of telehandler 6 Extend and lower the...

Page 54: ...ging Forks The attachment fork combination is the most frequently used combination Different loads may require changing forks with different ratings Figure 2 20 Changing Forks 1 Lower the boom with fo...

Page 55: ...mb button and move joystick backward to shift left fork to the right 3 Handle load the same as regular fork attachment refer to Section 2 13 2 15 2 Combination Fork Positioner Sideshift Attachment The...

Page 56: ...ppler is intended for handling single and multiple pipes Figure 2 24 Pipe and Pole Grappler Installation Procedure 1 Remove fork attachment or other attachment from boom and install pipe and pole grap...

Page 57: ...roach load with handler s clamps open 2 Position handler so that load is in the center of clamps 3 Close clamps by moving joystick rearward and transport load to placement site 4 Press and hold the le...

Page 58: ...pintle hook using sufficient chains cables 3 While helpers guide the load position load at placement point 2 15 8 Light material Bucket A material bucket has a high back and straight sides for cutting...

Page 59: ...the use of third party attachments on any of its Zoom Boom RTFL s 2 15 10 1 It is permissible to install and utilize third party attachments provided they do not elevate personnel and the following c...

Page 60: ...2 16 1 Loading and Tie down 1 Ensure telehandler is level prior to loading 2 Fully lower and retract boom and raise outriggers if equipped 3 Ensure ramps are correctly positioned 4 Using a spotter ca...

Page 61: ...ie down points are fully accessible 2 Carefully fasten tow chains to tie down points on either front or rear of telehandler frame 3 Remove chocks from wheels 4 Enter cab and fasten seatbelt 5 Ensure t...

Page 62: ...am of coolant flows out of the engine vent then close the engine vent NOTE When filling the radiator do not exceed 3GPM fill rate 4 Fill radiator completely through the reserve tank filler neck until...

Page 63: ...S FOPS operator compartment 4 wheel drive External rear view mirrors Automatically activated S A H R parking brake Electric horn and reverse warning alarm Anti skid floor and steps Quick disconnect ca...

Page 64: ...ngle Boom raise Boom lower Carriage roll forward Carriage roll back Frame level right stop to stop Frame level left stop to stop 238 C Measured with boom fully retracted Under no circumstances should...

Page 65: ...pment 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...

Page 66: ...W40 CC SF Coolant Type Differential SAE 80W 90 GL 5 T r a n s m i s s i o n Type ATF Dexron III Capacity 6 3 gal 24 L A x l e s Differential SAE 80W 90 GL 5 Planetary Wheel Ends Type Anti wear ISO Gr...

Page 67: ...icator A Proximity Sensor A Transmission Lifting Attachment A Grease Fittings Grease Fittings on Frame B Grease Fittings on Boom Assembly B Operator s Cab ROPS FOPS A Seat A Pedals A Manual A Operator...

Page 68: ...est Frame Levelling and Level Indicator Wheel Tire Assembly Test Frame Level Lock Drive Axle Test Accelerator Pedal Steer Cylinder Assembly Test Driving and Service Brake Functions Steer Linkage Test...

Page 69: ...then start engine 2 A All turbo engines air cleaner and exhaust must be sealed during transport NOTICE Transportation Reminder Ensure engine air cleaner and exhaust are sealed during transportation 3...

Page 70: ...Fuel Refill fuel tank with ultra low sulfur diesel fuel only If equipped 8 Reserve Steering Accumulator Indicates when steering is using accumulator reserve pressure If equipped 9 Brake Information De...

Page 71: ...ped with a back up alarm 13 This unit is equipped with rear axle tilt lock which is energized when red light is lit Never attempt to level frame when boom is elevated or when red light is lit WAR NING...

Page 72: ...tlined risks associated with this telehandler prior to operation 4 Head Tail Lights Identifies the location of light switches If equipped 5 Boom Work Lights Identifies the location of light switches I...

Page 73: ...ilt console lock lever 10 3 Function Joystick Boom Boom and fork tilt functions joystick 11 Daily Check Label Check daily before operating the telehandler 12 No Jewelry Caution Do not wear jewelry 13...

Page 74: ...ogo Skyjack logo white 2 Model Number Product Identifier 3 Open Door Squeeze to open cab door 4 Manual Storage Box Indicates location of operating manual Operator s Cab Enclosed Cab Only Labels Model...

Page 75: ...l for crushing hazards 4 Lift and Tie Down Points Only use these points for lifting or tying down 5 Skyjack Logo Skyjack logo white 6 Model Number Product Identifier 7 Body Crush Hazard Danger Crushin...

Page 76: ...6 2 bar 90 psi ZZ Tire Pressure Inflate tires to 90 psi maximum If equipped Tire Foam Filled Foam filled tires If equipped 12 Stay Clear Caution Stay clear 13 Auxiliary 2 3 Indicates auxiliary right...

Page 77: ...DEFG Boom Letters Indicates boom extension distance 17 Grease Grease point 18 Keep Chains Tight Maintain tension in chains If equipped 19 Boom Angle Indicator Indicates boom elevation angle Right Cab...

Page 78: ...pe Label Transmission dipstick and filler tube ATF Dexron III 4 Grease Grease point 5 Stay Clear Caution Stay clear 6 Crushing Hazard Danger Crushing hazard 7 Lift and Tie Down Points Only use these p...

Page 79: ...uct Identifier 3 Keep Chains Tight Maintain tension in chains If equipped 4 Grease Grease point 5 Stay Clear Caution Stay clear 6 Crushing Hazard Danger Crushing hazard 7 Fork Danger Caution Fork dang...

Page 80: ...Z Tire Pressure Inflate tires to 90 psi maximum If equipped Tire Foam Filled Foam filled tires If equipped 12 This tank is equipped with in tank oil heater Oil level must be sufficient to keep tank he...

Page 81: ...e these points for lifting or tying down 17 Crushing Hazard Refer to operating manual for crushing hazards 18 HYDRAULIC OIL ALL WEATHER TYPE SEE OPERATORS SERVICE MANUAL Hydraulic Oil Refill Hydraulic...

Page 82: ...e point 3 Stay Clear Caution Stay clear 4 Battery Disconnection Connection Procedure Follow these instructions to connect disconnect battery 5 Battery Disconnect Switch Battery disconnect If equipped...

Page 83: ...Cancer and Reproductive Harm https www p65warnings ca gov WARNING T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 84: ...T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

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