402505AC

MODELS ZB20032 ZB20044
Operating Manual
ZOOM BOOM Telehandlers
Part No. 402505AC-A August 2010

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 & Service (Europe)
Parts (North America) Unit 1 Maes Y Clawdd
Toll Free: 1-800-965-4626 Maesbury Road Industrial Estate
Toll Free Fax: 1-888-782-4825 Oswestry, Shropshire SY10 8NN UK
E-mail: parts@skyjack.com Phone: +44-1691-676-235
Fax: +44-1691-676-238
Skyjack Australia Pty Ltd. E-mail: info@skyjackeurope.co.uk
4 Coates Place
Wetherill Park Skyjack Brasil
New South Wales 2164 Alameda Júpiter, 710
Australia Loteamento American Park Empresarial
Tel: +61 (0) 28786 3200 Indaiatuba, SP, Brasil 13347-653
Fax: +61(0) 28786 3222 Tel: +55 19 3936 0132
The Safety Alert Symbol identifies important
safety messages on telehandlers, safety signs This Safety Alert Symbol means attention!
in manuals or elsewhere. When you see this
symbol, be alert to the possibility of personal Become alert! Your safety is involved.
injury or death. Follow the instructions in the
safety message.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
warning
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. 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.
ZB20032
TM
ZB20044 December 2007 Page 3

Table of Contents
Section 1 - About Your Telehandler
Read and Heed

Telehandler Definition...................................................................................................................................................7
Purpose of Equipment..................................................................................................................................................7
Use of Equipment.........................................................................................................................................................7
Manual...........................................................................................................................................................................7
Operator........................................................................................................................................................................7
Service Policy and Warranty.........................................................................................................................................7
Optional Accessories....................................................................................................................................................7
Scope of this Manual....................................................................................................................................................7
Safety Rules
Operator Safety Reminders..........................................................................................................................................8
Electrocution Hazard....................................................................................................................................................9
Safety Precautions......................................................................................................................................................10
Section 2 - Operation
2.1 General.............................................................................................................................................................17
2.1-1 Operator Qualifications.....................................................................................................................17
2.1-2 Operator’s Responsibility for Maintenance......................................................................................17
2.1-3 Maintenance and Inspection Schedule............................................................................................17
2.1-4 Owner’s Inspections.........................................................................................................................17
2.2 Major Components .........................................................................................................................................18
2.3 Major Assemblies ............................................................................................................................................19
2.3-1 Frame . .............................................................................................................................................19
2.3-2 Cab...................................................................................................................................................19
2.3-3 Boom Assembly................................................................................................................................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, Seat, Manual Storage Box . ..................................................................................20
2.5-3 Operator’s Cab Controls..................................................................................................................21
2.6 Component Identification.................................................................................................................................25
2.6-1 Main Power Disconnect Switch (If Equipped)..................................................................................25
2.6-2 Optional Reserve Steering (If Equipped).........................................................................................25
2.6-3 Optional Secondary Park Brake (If Equipped).................................................................................25
2.7 Operator’s Responsibility.................................................................................................................................26
2.8 Visual and Daily Maintenance Inspections .....................................................................................................27
2.8-1 Labels...............................................................................................................................................27
2.8-2 Electrical...........................................................................................................................................27
2.8-3 Safety Switches................................................................................................................................27
2.8-4 Mirrors...............................................................................................................................................27
2.8-5 Hydraulic...........................................................................................................................................28
2.8-6 Cylinders...........................................................................................................................................28
2.8-7 Frame................................................................................................................................................28
2.8-8 Engine Compartment.......................................................................................................................30
2.8-9 Transmission.....................................................................................................................................31
2.8-10 Boom................................................................................................................................................32
2.8-11 Lifting Attachment.............................................................................................................................32
2.8-12 Grease Points...................................................................................................................................32
2.8-13 Operator’s Cab.................................................................................................................................34
ZB20032
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Page 4 December 2007 ZB20044

Table of Contents
Section 2 - Operation (Continued)
2.9 Function Tests..................................................................................................................................................35

2.9-1 Operator’s Cab Controls..................................................................................................................35
2.10 Start Operation.................................................................................................................................................44
2.10-1 Starting the Engine...........................................................................................................................44
2.10-2 Driving the Telehandler.....................................................................................................................45
2.10-3 Driving on Slopes.............................................................................................................................45
2.10-4 Steering the Telehandler...................................................................................................................46
2.10-5 Leveling the Telehandler...................................................................................................................46
2.10-6 Raising or Lowering Boom...............................................................................................................46
2.10-7 Extending or Retracting Boom.........................................................................................................47
2.10-8 Handling Loads................................................................................................................................47
2.10-9 Parking and Shutting-down the Telehandler....................................................................................48
2.11 Refueling Procedure (Diesel Fuel Only)...........................................................................................................48
2.12 Use of the Capacity Charts..............................................................................................................................50
2.12-1 Examples on Reading the Capacity Chart.......................................................................................51
2.13 Attachments Installation...................................................................................................................................52
2.13-1 Removing Attachments using the Quick Attach Feature.................................................................52
2.13-2 Installing Attachments using the Quick Attach Feature...................................................................52
2.14 Handling Loads................................................................................................................................................53
2.14-1 Handling Loads at Ground Level.....................................................................................................53
2.14-2 Handling Loads at Variable Heights.................................................................................................54
2.14-3 Adjusting Forks.................................................................................................................................55
2.14-4 Changing Forks................................................................................................................................55
2.15 Optional Attachments.......................................................................................................................................56
2.15-1 Fork Positioner..................................................................................................................................56
2.15-2 Combination fork Positioner/Sideshift Attachment..........................................................................56
2.15-3 Bridge Stripper Attachment..............................................................................................................57
2.15-4 Pipe and Pole Grappler....................................................................................................................57
2.15-5 Pipe and Pole Handler......................................................................................................................58
2.15-6 Hydraulic Winch................................................................................................................................58
2.15-7 Jib Boom Attachment (5-ft.).............................................................................................................59
2.15-8 Light-material Bucket........................................................................................................................59
2.15-9 Coil Boom.........................................................................................................................................60
2.16 Loading and Transporting................................................................................................................................62
2.16-1 Loading and Tie-down......................................................................................................................62
2.16-2 Towing the Telehandler.....................................................................................................................63
2.17 Tables...............................................................................................................................................................64
2.18 Labels...............................................................................................................................................................70
List of Tables
2.1 Standard and Optional Features......................................................................................................................64

2.2 Specifications and Features.............................................................................................................................65
2.3 Tire/Wheel Specifications.................................................................................................................................66
2.4 Recommended Fluids/Lubrication...................................................................................................................67
2.5 Maintenance and Inspection Schedule ..........................................................................................................68
2.6 Operator’s Checklist.........................................................................................................................................69
ZB20032
TM

Notes
ZB20032
TM

Section 1 - About Your Telehandler Read and Heed
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
Telehandler Definition
A material handler designed primarily as a fork truck with a pivoting telescopic boom which enables it to pick and
place loads at distances as well as various lift heights.
1
Purpose of Equipment
The SKYJACK telehandlers are designed to lift, handle and transport agricultural or industrial products by means
of specific attachments.
Use of Equipment
The telehandler is a highly maneuverable, mobile work station. Lifting, handling and driving must be on a flat, level,
compacted surface. It can be driven over uneven terrain only when the boom is fully lowered.
Manual
The operating manual is considered a fundamental part of the telehandler. It is a very important way to communicate
necessary safety information to users and operators. A complete and legible copy of this manual must be kept in
the provided weather-resistant storage compartment on the telehandler at all times.
Operator
The operator must read and completely understand both this operating manual and the safety panel label located on
the telehandler and all other warnings in this manual and on the telehandler. Compare the labels on the telehandler
with the labels 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 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. Contact SKYJACK Service Department for warranty statement extensions or
exclusions.
Optional Accessories
The SKYJACK telehandler is designed to accept a variety of optional accessories. These are listed under “Optional
Attachments” in Section 2. Operating instructions for these options (if equipped) are located in Section 2 of this
manual.
For non-standard components or systems, contact the SKYJACK Service Department at
( : 800 275-9522
7 : 630 262-0006
Include the model and serial number for each applicable telehandler.
Scope of this Manual

a. This manual applies to the ANSI/ASME/ITSDF and CSA versions of the ZB20032 & ZB20044 telehandlers.
- Equipment identified with “ANSI” meets the ANSI/ITSDF B56.6 standard.

- Equipment identified with “CSA” meets the CSA B335-04 standard.
b. CSA (Canada)
Operators are required to conform to national, territorial/provincial and local health and safety regulations
applicable to the operation of this telehandler.
c. ANSI (United States)

Operators are required by the current ANSI standards to conform to national, territorial/provincial and local
health and safety regulations applicable to the operation of this telehandler.
ZB20032
TM

Safety Rules Section 1 - About Your Telehandler
warning
Failure to comply with your required responsibilities in the use and operation of the telehandler
could result in death or serious injury!
Operator Safety Reminders

A study conducted by St. Paul Travelers showed that most accidents are caused by the failure of the operator to
follow simple and fundamental safety rules and precautions.
You, as a careful operator, are 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
telehandler.
Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety
devices to protect your eyes, ears, hands, feet and body.
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.
ZB20032
TM

Section 1 - About Your Telehandler Safety Rules
Electrocution Hazard
This telehandler is not electrically insulated. Use extreme caution around high-voltage overhead power lines
and maintain a Minimum Safe Approach Distance (MSAD) of 10 feet from source of power. Adhere to all federal/
national, state/provincial, or local safety regulations for your own protection.
No part of telehandler or 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
250,000 20 feet
DANGER
Never approach any power line with any part of telehandler. Use extreme caution; serious injury
or death can result with contact from any power line.
IMPORTANT
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.
ZB20032
TM

Safety Precautions
Know and understand all safety precautions before going on to the next section.

WARNING
• DO NOT use telehandler
DO NOT operate this telehandler without as a man lift or equip
proper authorization and training. Failure this telehandler with a
to avoid this hazard could result in death personnel work platform.
or serious injury.

warning
Failure to heed the following safety
precautions could result in tip over,
• DO NOT use fork carriage
falling, crushing, or other hazards leading
attachment as a crane.
to death or serious injury.
• MAKE SURE all DANGER, WARNING, CAUTION

and INSTRUCTIONAL DECALS are in place
and can be read. Clean or replace decals as

required.
• KNOW all national, state/provincial and local rules

• DO NOT elevate the
which apply to your telehandler and jobsite.
boom in windy or gusty
conditions.
• WEAR all the protective clothing and personal
safety devices issued to you or called for by job

conditions.
• DO NOT wear loose

• DO NOT drive with boom
clothing, dangling
elevated.
neckties, scarves, rings,
wristwatches or other
jewelry while operating
this telehandler.

• DO NOT operate on
surfaces not capable of
• DO NOT climb on this
holding the weight of the
vehicle for any reason.
telehandler; including the
rated load (e.g., covers,
drains, and trenches).

• DO NOT maneuver a load
• DO NOT stand on forks.
while moving. This greatly
Failure to heed could
increases the chance of
result in death or serious
spills and injury.
injury.
ZB20032
TM

Safety Precautions (Continued)

• DO NOT exceed the maximum safe operating
slope.
• DO NOT lower the boom
unless the area below is
clear of personnel and
obstruction.
• DO NOT elevate the boom

while the telehandler is on
a truck, forklift or other
device or vehicle.

• ENSURE that there are no
• DO NOT use frame personnel or obstructions
leveling when boom in the path of travel,
is elevated. It is including blind spots.
recommended that frame
leveling be used only when • BE AWARE of blind
boom is retracted and in spots when operating the
the lowered position. telehandler.

• ALWAYS Keep head,
arms, hands, legs and all
• DO NOT use the frame other body parts inside
leveling mechanism to the operator’s cab.
compensate for swinging
loads.

• DO NOT enter the danger area under or around • AVOID jerks and sudden
the boom when forks are off the ground or while stops.
engine is running.

• AVOID entanglement
with ropes, cords or
hoses.
ZB20032
TM


• BE AWARE of all obstructions while traveling.
Check for clearance before traveling between • ALWAYS wear your seat
obstacles. belt when operating this
vehicle.

• KNOW the weight of the
load you are transporting.
Never lift more than the
lifting capacity at any given
• USE CAUTION when extension or elevation of
boom is fully extended. the boom as listed on the
The further out the boom capacity charts.
is extended, the less load
telehandler can support.

• CHECK for cracks and
signs of stress.
• USE CAUTION when
placing loads at high
elevations and on downhill
slopes.
• TRAVEL SLOWLY over

rough terrain.
• WALK AROUND the

telehandler before
operation and check
for any visible signs of
damage or malfunction. • If operation in
areas with holes or
dropoffs is absolutely
necessary, ensure that
all 4 wheels or outriggers
• ALWAYS maintain three (if equipped) have
points of contact when contact with firm surface.
entering vehicle. Use Then level the frame.
provided hand-holds and Once frame is level the boom can be elevated.
steps only. After elevation, the drive function must not be
activated.
ZB20032
TM


• DRIVE DOWNHILL • SECURE loose loads

UNLOADED. Without with chains or straps to
a load, the back end decrease potential of
is the heaviest part of spills or injury to others.
the telehandler. Driving
downhill decreases
potential for tipover.

• TETHER LOADS that
• DRIVE UPHILL may swing, keeping
LOADED. When holding them close to the ground.
a load, driving uphill Provide ample clearance
decreases potential for for personnel to guide the
load to slip out. load safely.

• BE AWARE of the
telehandler’s travel
• ALWAYS LEVEL FRAME 2 envelope, especially when
before elevating the turning. Keep sufficient
boom clearance at all times
1 between the telehandler
and any obstacles or
people.
• WHEN
TRANSPORTING
LOADS fully retract the • KEEP OTHERS AWAY
boom, keep the load low at all times during
to the ground and forks operation.
tilted back slightly. This is
the most stable position
possible for the vehicle.

• KEEP forks close to the
ground when in motion
to increase telehandler • CHECK lights (if equipped)
stability and decrease for proper function before
potential for injury to operating.
others. When fully
stopped, lower forks
completely to the ground.

• ENSURE ALL tires are
• TILT forks backwards in good condition and
slightly when traveling to lug nuts are properly
decrease potential of load tightened.
slipping off.
ZB20032
TM


• DO NOT alter or disable safety devices. • DO NOT change steering mode while the
telehandler is traveling. Change the steering
• DO NOT burn or drill holes in forks. Modifying mode only when telehandler is stopped, and
any part of telehandler or attachment affects its wheels aligned straight ahead.
capacity and/or stability.
• ALWAYS look in the direction of travel. Reduce
• DO NOT try to start the telehandler by pushing speed and be careful especially when traveling in
or towing. Such operation may cause severe reverse and/or turning. Bring the telehandler to a
damage to the transmission - Refer to Section 2. complete stop before changing the direction of
travel.
• IF DRIVING ON ROADS OPEN TO PUBLIC
TRAFFIC respect the local regulations. • STAY CLEAR of pinch points and rotating parts
on the material handler. Getting caught in a pinch
• THE OPERATOR’S CAB provides a falling point or a moving part can cause serious injury
object protection structure (FOPS) and a rollover or death. Before performing any maintenance on
protection structure (ROPS). Do not make any telehandler, follow the shutdown procedure in
modification to this structure. If damaged, the Section 2.10-9.
cab cannot be repaired. It must be replaced.
• DO NOT position the telehandler against another
• STUNT driving and horseplay are prohibited. object to steady the load.
• ALWAYS USE FRONT steering when traveling at • SHUT DOWN by positioning the telehandler in
high speeds; i.e., on highways or public roads. a safe location. Lower forks to ground, apply the
parking brake, move all controls to ‘neutral’ and
allow engine to run at low idle for 3 to 5 minutes
after a full load operation. Stop engine and
remove ignition key to prevent unauthorized use.
Block tires.
WARNING
Always engage park brake and shut off
engine before leaving the operator’s
cab.
ZB20032
TM


Jobsite Inspection
WARNING • Do not use in hazardous locations.
• Perform a thorough jobsite inspection prior to
Entering and exiting the telehandler operating the telehandler, to identify potential
should only be done using the three hazards in your work area.
points of contact. • Be aware of moving equipment in the area. Take
appropriate actions to avoid collision.
• Use only equipped access openings.
• Enter and exit only when the telehandler
is in the fully retracted position.
• Do use three points of contact to enter and exit

the cab.
• Three points of contact means that two hands

and one foot or one hand and two feet are in
contact with the telehandler or the ground at all
times 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 or modifications not approved by
the manufacturer.
• has safety devices which have been altered or
disabled.
• 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.
ZB20032
TM

Notes
ZB20032
TM

2.0 Operation 2.1-2 Operator’s Responsibility for

This section provides the necessary information needed Maintenance
to operate the telehandler. It is important that the user
reads and understands this section before operating WARNING
the telehandler.
Maintenance must be performed by
trained and competent personnel who are
2.1 General familiar with mechanical procedures.
In order for this telehandler to be in good working
condition, it is important that the operator meets the
2
Death or serious injury could result
necessary qualifications and follows the maintenance
from the use of a telehandler that is not
and inspection schedule referred to in this section.
properly maintained or kept in good
working condition.
2.1-1 Operator Qualifications
• Only trained and authorized personnel shall be
• The operator must be sure that the telehandler
permitted to operate the telehandler.
has been properly maintained and inspected
before using it.
• Safe use of this telehandler requires the operator
to understand the limitations and warnings,
• The operator must perform all the daily inspections
operating procedures and operator’s responsibility
and function tests found in Table 2.5, even if
for maintenance. Accordingly, the operator must
the operator is not directly responsible for the
understand and be familiar with this operating
maintenance of this telehandler.
manual, its warnings and instructions, and all
warnings and instructions on the telehandler. 2.1-3 Maintenance and Inspection Schedule
• The inspection points covered in Table 2.5 indicate
• The operator must be familiar with employer’s work
the areas of the telehandler to be maintained or
rules and related government regulations and be
inspected and at what intervals the maintenance
able to demonstrate the ability to understand and
and inspections are to be performed.
operate this make and model of telehandler in the
presence of a qualified person. • The actual operating environment of the telehandler
may affect the maintenance schedule.
WARNING
DO NOT operate this telehandler without WARNING
proper authorization and training. Failure Use original or manufacturer-approved
to avoid this hazard could result in death parts and components for the
or serious injury. telehandler.
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 for
recommended maintenance and inspection areas and
intervals.
ZB20032
TM

2.2 Major Components
Boom Assembly
Boom Angle Indicator
Attachment Tilt
Cylinders
Boom Lift Cylinder
Engine Air Intake
2004
4
Frame Level Cylinders
Fork Carriage
Attachment
Outriggers Rear Axle Rear Axle

Front Axle Operator’s Lock Cylinder and Tire
and Tire Cab
ZB20044 Telehandler
ZB20032
TM

2.3 Major Assemblies 2.4 Serial Number Nameplate

The telehandler consists of four major assemblies: the The serial number nameplate is located inside the
frame, boom assembly, attachment and cab. operator’s cab and lists the following:
2.3-1 Frame • Model number

The frame is a one-piece weldment that supports • Serial number
the boom assembly. The parking brake is a pinion- • Maximum capacity
mounted disc brake on the front axle. ZB20032 and • Maximum lift height
ZB20044 models are equipped with a dual service • Maximum machine weight without attachment
brake system. • Original supplied attachments
• Year of manufacture
2.3-2 Cab • Voltage
The cab is the safety structure enclosing the operator.
It also furnishes the controls of the telehandler.
2.3-3 Boom Assembly

The boom is mounted on the frame and supported
by lift cylinders on each side of the frame. The boom
assembly consists of main boom section and primary
boom section in the ZB20032 model. The ZB20044
model has a third boom section.
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 standard attachment is a fork carriage
attachment. The standard carriage is available in 60”,
72” and 84” widths. Optional attachments include
combination fork positioner/sideshift attachment, fork
positioner, pipe and pole clamp and grapple, coil
boom, bridge stripper, light material bucket, jib boom,
& winch attachment. Refer to Section 2.14 for optional
attachments.
ZB20032
TM

Component Identification Section 2 - Operation
2.5 Component Identification

The following descriptions are for identification,
explanation and locating purposes only.
2.5-1 Boom Angle Indicator

The boom angle indicator is a quick reference for the Seat belt
operator to determine the boom’s angle of elevation in
reference to the horizontal.
Ride Control
Adjustment
Height Fore/Aft
Adjustment Lock Lever
Figure 2-2 Telehandler Seat
Boom Seat
Angle The telehandler seat is equipped with devices which
Indicator allow for the adjustment of seat height and distance
from the controls. Adjust the seat so that foot pedals,
Figure 2-1 Boom Angle Indicator steering wheel and instrument panel controls are within
easy reach of the operator.
The angle indicator has degree numbers from -20° to
+80°. The numbers should be visible to operator at all The height adjustment is located on the front side of
times. Capacities listed in capacity flip charts are based the seat and is operated by turning the rotary knob.
on and vary with the boom angle of telehandler. Clockwise rotation lowers the seat, counter clockwise
raises the seat.
2.5-2 Operator’s Cab
The operator’s cab allows vision from all sides and is The ride control is located on the left of the seat and
equipped with a rollover and falling object protective is also operated by means of a rotary knob. Clockwise
structure. rotation decreases the firmness while counterclockwise
rotation increases the firmness.
WARNING
The fore and aft lock lever is located on the front-left
The operator’s cab provides a falling corner of the seat. Pushing the lever to the left unlocks
object protection structure (FOPS) and the seat, allowing fore and aft adjustment.
a rollover protection structure (ROPS).
Do not make any modification to this
WARNING
structure. If damaged, the cab cannot be
repaired. It must be replaced. The seat belt must be worn at all times.
A fully-enclosed cab with windows and door is Manual Storage Box

available as an option. Included in this option is the T h i s w e a t h e r- r e s i s t a n t b o x
windshield wiper, interior light and air heater/defroster. is mounted at the back of the
Air conditioner is also available as an option for fully operator’s seat. It contains
enclosed cab. operating manual and other
important documentation. The
The operator’s seat is equipped with a seat belt. Use this operating manual for this make and
seat belt at all times when operating the telehandler. model of telehandler must remain
with the telehandler and should be
stored in this box.
ZB20032
TM

Section 2 - Operation Component Identification
2.5-3 Operator’s Cab Controls
1
WARNING
5
6 7
2
DEC-016
3
DANGER FORKLIFT SIGNALS ZB10044/10056
ELECTROCUTION 5 1
HAZARD
21
EVERY 40 HRS
OF SERVICE UNLESS
PSI
NOTED
1
KEEP CLEAR
CLEAN AND OIL
BRAKE PEDAL
2 PIVOT PIN
GREASE AXLE
FRONT & REARPIVOT BEARINGS
10 4 PLS
DEATH OR SERIOUS 3 GREASE LIFT CYLINDERS
CONTACT WITH INJURY CAN BOTH SIDES 4 TOP & BOTTOM
RESULT FROM 1. STOP
PLS
LOAD, MACHINE 4 GREASE MAIN
IF THEY BECOME OR 2. RAISE LOAD
BOTH SIDES 2 BOOM PIVOT BEARING PINS
ELECTRICALLY VEHICLE 3. LOWER LOAD PLS
CHARGED 2 5 GREASE AXLE
LOCK CYLINDER
DEC-002 6 TOP & BTM
6 8 GREASE AXLE
7
22
PSI
FRNT & REAR 4KING PINS
PLS
4
7 GREASE SLIP JOINT
17 15 15 FRNT & REAR 2 ON DRIVE SHAFT
14 PLS
18 8 GREASE DRIVE
FRNT & REAR 4 SHAFT U JOINT
PLS
12 9 GREASE FRAME
4. TILT FORKS RIGHT TOP & BOTTOM, LEVEL CYLINDER
5. TILT FORKS LEFT 3
BOTH CYLINDERS
11
6. TILT FORKS UP 16 15 10 GREASE OUTRIGGER
PINS
15 11 GREASE SLAVE
TOP & BOTTOM,CYLINDER
BOTH CYLINDERS
12 GREASE CARRIAGE
TOP & BOTTOM, TILT CYLINDER
13 BOTH CYLINDERS
13 GREASE CARRIAGE
PIVOT BEARINGS
14 GREASE EXTENSION
9 CHAIN AND ROLLER
7. TILT FORKS DOWN 11 15 GREASE SLIDE 3 PLS
8. MOVE LOAD BACKWARD PADS 30 PLS
1. Only one person

2. Make sure the
INSTRUCTIONS
to be signalman
operator can see
TO SIGNAL MEN
3. Signalman must
9. MOVE LOAD FORWARD
watch the load––

the operator is watching
18
16
17
GREASE RETRACT
GREASE HOSE
OIL EXTENSION
CHAIN ROLLERS
ROLLERS 2 PLS
AFTER 500 HRS CHAINS
3 PLS
LIGHTS
and is able to acknowledge you 10 OF SERVICE
the you
signal given 4. Never raise or PSI 19 CHECK TORQUE
lower the load over DAILY FOR FIRST ON WHEEL LUG NUTS
3
workmen, warn other 20
WATCH FOR OVERHEAD them to keep out
of the way 19 450-500 FT-LBS 150 HRS OF SERVICE DEC-178
LINES OR OTHER OBSTRUCTIONS
20 CHECK TIRE PRESSURE
DEC-024 65-70 PSI
CHART FOR REFERENCE 21 CHECK AXLE LOCK
ONLY. SEE SERVICE 175-200 PSI, EVERY ACCUMULATOR PRESSURE
MANUALS FOR AND OPERATOR'S 6 MONTHS
DETAILED SERVICE/MAINTENANCE 22 CHECK BRAKE
ACCUMULATOR
475-500 PSI, EVERY
INFORMATION. PRESSURE
6 MONTHS
DEC-302





 
The
9

 



 

Reach

 


 
4



Machine
K
JOYSTIC
ON FORWARD
3 FUNCTIHOLD
TILT
AND TILT
PUSH FORK
FORK
BACK
FOR
LOWER
BOOM
BOOM
EXTEND
DEC-142
BOOM
RETRACT RAISE
BOOM
FRAME
LEVEL
EL
T F G I R
DEC-055
TH
10
CHECK DAILY
OPERATING
GENERAL: INSTRUCTIONS:
:Hydraulic Cylinders - Centre Load
on Forks
:Radiator and - Beware of Overhead
battery level Obstacles
:Hydraulic Hoses - Observe All
and Fittings Operating and
:Transmission - Bring Unit to Safety Decals
Fluid, Hydraulic a Full Stop Before on Machine
Oil - Use High Gear Changing Direction
for Road Travel
- Disengage Park of Unloaded Unit
Brake ONLY
AXLES: - Never Exceed
Rated Lifting
:Mounting Bolts - Feather Hydraulic Capacity -- See
Controls when Factory
:Wheel Studs/
Nuts
- Inspect Lift
Component( Mast Nearing Maximum Load Chart
:Oil Leaks at Components or Boom ) Chains, Mast/Boom Extension
Drive
:Two Wheel Drive Hubs and Differential - Cycle Each Rollers, Pins
and Welded
Units Only--Steer Hydraulic Function
Operation at Start of Day
to ensure Proper
BRAKES: TRAVELLING:
:Pedal Response
:Clean Mud and - Keep Telescopic
Debris from Brake Booms Fully
Pedal Assembly - Keep Carriage Retracted
Tilted Back to
- Travel with Load Avoid
at Lowest PracticalSpills
ELECTRICAL: - Always Have
Forks Height
:All Exposed - Travel in Reverse Pointed Up Hill on a Grade
Wiring if Load Obstructs
:Proper Operation Forward Vision
:Charging System of All Gauges PARKING PROCEDURE:
Ammeter/Voltmeter
1. Apply Park
Brake
12
ENGINE: 2. Place Transmission
in "NEUTRAL"
:Hoses 3. Park Machine
on Flat, Level
:Belts 4. Park Machine Surface or Chock
with Forks, Slightly Wheels
:Fluid Levels/ in Mud during
Leaks Winter Operation Clear of Ground to Avoid
Freezing
WORK SAFETY:
TIRES:
:Gouges, cuts, - No Riders at
punctures any time
:13:00 and 14:00 - Only Trained,
X24 Grader Lug Authorized Operators
:Rims -- Examine -- 65 - Operate Machine
for Cracks, Distortion,PSI Unloaded Only From Operator
Ring Assembly Lock - Use Only Approved Seat
- Do Not Use Personnel Platforms
Control Levers
- Never Make or Steering Wheel
any Unauthorized as Grab Handles
- Never Tilt Carriage Alterations or
when Personnel Adjustments
- Thoroughly
Read and Understand Platform is Used
Operator Manual
before Operating
"SPECIALISTS
IN ROUGH TERRAIN
FORKLIFTS"
1. Level Indicator - This level indicator allows 7. Boom/Attachment Joystick - This dual-axis
the operator to determine the left to right level lever controls the boom raise/lower and extend/
condition of the telehandler. retract functions. The lever returns to neutral when
released. The thumb button on top of handle
2. Wiper Switch (If equipped) - This switch turns selects the attachment tilt function.
wiper on or off and has two speeds.
To raise the boom, move joystick backward. To
3. Hourmeter - This gauge records accumulated lower the boom, move joystick forward.
operating time of the telehandler.
To extend the boom, move joystick to the right. To
4. Transmission Control Lever - This lever selects retract the boom, move the joystick to the left.
forward or reverse travel. The center position
is neutral. To select forward travel, push lever To tilt attachment forward, depress and hold
forward; for reverse travel pull lever backward. thumb button while moving joystick forward. To tilt
Twist handle grip to select speed range. attachment backward, depress and hold thumb
button while moving joystick backward.
5. 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 2.10-4).
6. Heater Fan switch (if equipped) - This switch

selects heater fan speed.
ZB20032
TM

14
WARNING
5
DEC-016
7 IMPORTANT
8 WARNING
No Riders
DEC-013A
WARNING
THIS VEHICLE IS EQUIPPED WITH A
BACKUP 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
WARNING
1. ALWAYS LEVEL MACHINE
BEFORE RAISING BOOM.
2. ALWAYS LOWER AND RETRACT
BOOM BEFORE MOVING MACHINE.
3. NEVER USE FRAME LEVELLING
WHEN BOOM IS ELEVATED.
DEC-099
WARNING
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.
DEC-100
Extending ourselves
for you.






ELECTROCUTION 5 1

HAZARD
21
EVERY 40 HRS
OF SERVICE UNLESS
PSI
NOTED
1
KEEP CLEAR
CLEAN AND OIL
BRAKE PEDAL
2 PIVOT PIN
GREASE AXLE
4 PLS
DANGER
10
RESULT FROM PLS
20044
LOAD, MACHINE 1. STOP
 
4 GREASE MAIN
IF THEY BECOME OR
ELECTRICALLY VEHICLE
2. RAISE LOAD
3. LOWER LOAD BOTH SIDES 2 BOOM PIVOT BEARING PINS
PLS 
LOCK CYLINDER
DEC-002 6 TOP & BTM
6 8 GREASE AXLE
7
22
PSI
PLS
4
17 15 15
14
18
7
8
GREASE SLIP JOINT
FRNT & REAR 2
GREASE DRIVE
PLS
ON DRIVE SHAFT
 
DO NOT OPERATE  

PLS
12 9 GREASE FRAME
BOTH CYLINDERS
11
PINS
15 11 GREASE SLAVE
 
THIS MACHINE
BOTH CYLINDERS
12 GREASE CARRIAGE
TILT CYLINDER
 
TOP & BOTTOM,
13 BOTH CYLINDERS
13 GREASE CARRIAGE
PIVOT BEARINGS
14 GREASE EXTENSION
9 CHAIN AND ROLLER
WITHOUT SEAT
3 PLS
LIGHTS
7. TILT FORKS DOWN 15 GREASE SLIDE
 
11 PADS 30 PLS
8. MOVE LOAD BACKWARD
9. MOVE LOAD FORWARD 16 GREASE RETRACT
CHAIN ROLLERS
INSTRUCTIONS
TO SIGNAL MEN 17 GREASE HOSE 3 PLS
1. Only one person ROLLERS 2 PLS
to be signalman
3. Signalman must 18 OIL EXTENSION
 
2. Make sure the
operator can see
and is able to acknowledge you
the operator is watching AFTER 500 HRS CHAINS
10 OF SERVICE
BELT FASTENED
the you
signal given 4. Never raise or PSI 19 CHECK TORQUE
3
 
20 CHECK TIRE
DEC-024 PRESSURE 65-70
21 CHECK AXLE PSI
CHART FOR REFERENCE LOCK
ACCUMULATOR
475-500 PSI, EVERY
6 MONTHS
DEC-023
DEC-302

IMPORTANT 

MPORTANT
1. TIGHTEN WHEEL NUTS DAILY 

 FIRST 150 HOURS OPERATION 





2. CHECK AXLE & SPRING 
 
MOUNTING BOLTS REGULARLY
The

  DEC-022



 

Reach

 


 


PARK AXLE DIFF CHARGE


Machine 3 FUNCTIHOLD
AND TILT
ON
JOYSTIC
FORWARD
FORK
K
TILT
IMPORTANT BRAKE LOCK LOCK PRESSURE
DEC-320
ALL TURBO-ENGINES
PUSH FORK BACK
FOR
LOWER
BOOM
AIR CLEANER AND EXHAUST

BOOM
EXTEND
DEC-142
BOOM
RETRACT RAISE
MUST BE SEALED DURING

BOOM
TURN KEY TO ON, WAIT FOR GAUGE

TRANSPORT DEC-052 TO INITIALIZE, THEN START ENGINE.
DEC-322
BRAKE ACTUATED
STEERING PARKING SECONDARY OUTRIGGERS TURN SIGNALS
TRANSMISSION
LEFT RIGHT
HORN
DISCONNECT BRAKE BRAKE DEC-308E
NORMAL
LEFT RIGHT
OPERATION ROUND ON ON DOWN DOWN ON ON
12
FRAME
9
LEVEL
EL
T F G I R
DEC-055
TH
TRANSMISSION FRONT
11
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
ONLY CRAB OFF OFF UP UP400774 OFF OFF
DEC-216
CHECK DAILY
10
OPERATING
on Forks
for Road Travel
Brake ONLY
Rated Lifting
:Wheel Studs/
Nuts
- Inspect Lift
Drive
and Welded
to ensure Proper
BRAKES: TRAVELLING:
:Pedal Response
Tilted Back to
Forks Height
Ammeter/Voltmeter
1. Apply Park
Brake
in "NEUTRAL"
on Flat, Level
Freezing
WORK SAFETY:
TIRES:
punctures any time
Ring Assembly - Use Only Approved
13
Lock Seat
Personnel Platforms
- Do Not Use
Control Levers
- Thoroughly
Operator Manual
before Operating
15 16
"SPECIALISTS
IN ROUGH TERRAIN
FORKLIFTS"
8. Frame Level / Optional Attachment Joystick d) To operate a typical clamping or out function, move
- This joystick controls the relationship of the
telehandler frame to the front axle and controls joystick “ ” forward. Move joystick “ ”
optional attachments’ functions. The lever returns backward to operate an in function or to open
to neutral when released. a clamp.

a) To level frame to the right, move joystick to the Refer to Section 2.14 for optional attachments
operating instructions.
right “ ”. Move joystick to the left “ ”, to
level frame to the left. 9. Light Switches (If Equipped) - These switches
turn lights on or off.
b) Depress and hold the “ ” right thumb button on
the rocker switch and move the joystick forward 10. Boom Controller Console Lever - This lever
allows the operator to adjust the position of the
“ ” to operate a right-out function. Depress and controller box.
hold the “ ” right thumb button and move joystick
11. Accelerator Pedal - Depress pedal to increase
speed and release pedal to decrease speed.
backward “ ” to operate a right-in function.
12. Service Brake Pedal - The service brake is
c) Left-out function is operated by depressing and foot operated and is used to decrease speed or
holding “ ” left thumb button on rocker switch stop.
and moving joystick “ ” forward. Moving
13. Transmission Lever Neutral Lock Switch - This
two-position switch locks/unlocks forward or
joystick “ ” backward while pressing and
reverse movement of transmission lever.
holding the left thumb button “ ” on rocker switch
will operate a left-in function.
14. Capacity Charts - This set of charts indicates
operating limits specific to a telehandler model
and attachments. Refer to Section 2.11.
ZB20032
TM

Section 2 - Operation Component Identification
IMPORTANT
23
WARNING WARNING
WARNING WARNING
BACKUP ALARM 1. ALWAYS LEVEL MACHINE THIS UNIT IS EQUIPPED WITH REAR
BEFORE RAISING BOOM. AXLE TILT LOCK WHICH IS
ALARM MUST SOUND WHEN BACKING ENERGIZED WHEN RED LIGHT IS LIT.
No Riders
IT IS THE DRIVER'S RESPONSIBILTY BOOM BEFORE MOVING MACHINE. NEVER ATTEMPT TO LEVEL FRAME
BE SURE BACKUP ALARM IS OPERATING 3. NEVER USE FRAME LEVELLING WHEN BOOM IS ELEVATED OR
DEC-013A
DEC-109 WHEN BOOM IS ELEVATED. WHEN RED LIGHT IS LIT.
DEC-099 DEC-100
Extending ourselves
for you.



24




DANGER
20044

 
 
 
DO NOT OPERATE
 
THIS MACHINE  
WITHOUT SEAT  
 
BELT FASTENED  
DEC-023

MPORTANT
17
IMPORTANT 


FIRST 150 HOURS OPERATION 


DEC-022
IMPORTANT
ALL TURBO-ENGINES
PARK
BRAKE
AXLE
LOCK
DIFF
LOCK
CHARGE
PRESSURE
DEC-320
29
MUST BE SEALED DURING TURN KEY TO ON, WAIT FOR GAUGE
DEC-322
BRAKE ACTUATED
TRANSMISSION
LEFT RIGHT
HORN
NORMAL
LEFT RIGHT
TRANSMISSION FRONT
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
DEC-216
18 19 20 21 13 22 15 16
15. Ignition Switch - This is a three-position, anti- 18. Steer Mode Switch - This switch has three
restart switch. positions to allow selection of round steer, front
steer and crab steer. Refer to Section 2.10-4 for
When in “ ” off position, it turns the engine off steering procedure.
and key can be removed. When in “ ” on position,
it provides power to ignition and auxiliary circuits. 19. Parking Brake Switch - This switch controls the
When in “ ” start position, it starts the engine; application and release of parking brake.
when released, key returns to “ ” on position.
20. Secondary Park Brake Switch (If Equipped) -
16. Horn Button - This button sounds an automotive- This switch controls the application and release
type horn. of secondary park brake.
17. Transmission Disconnect Override - This is 21. Left and Right Outrigger Switches (If Equipped)
a two-position rocker switch used for ramping - These momentary switches control extension
operations only. and retraction of left and right outriggers.

Select rocker switch to forward “ ” position for Select switches to forward “ ” position to
normal operation. extend outriggers.

While in this position, the transmission will return
Select switches to backward “ ” position to
to neutral automatically upon application of the
retract outriggers.
brake.
22. Left and Right Turn Signals (If Equipped) -
Select rocker switch to backward “ ” position These rocker switches control left and right turn
when operating on a slope. signals located on both the front and rear of the
telehandler.
While in this position, the transmission will remain
in gear. Note
Turn on both signals switches to use as
emergency flashers.
ZB20032
TM

23
25
29
24
28
26 27
23. Powerview Electronic Dash Display - This 27. Axle Lock Light - This light indicates frame
graphical LCD screen enables the operator to view leveling is in slow/controlled mode, or locked
engine parameters and service codes. The keypad mode when park and/or foot brakes are applied.
on the Powerview is a capacitive touch sensing
system. Refer to service manual for complete 27. Brake Charge Pressure Light - This light
Powerview functions and operations. illuminates when service brake accumulator
pressure in either side of the dual service brake
24. Fuel Gauge - This gauge displays level of fuel in system is low. Park telehandler safely and have it
fuel tank. serviced immediately.
25. Transmission Oil Temperature Gauge - This

gauge displays transmission oil temperature.
26. Parking Brake Indicator Light - This light

indicates parking brake switch is activated.
28. Secondary Park Brake Light (If Equipped) - This

light indicates secondary park brake switch is
activated.
ZB20032
TM

Section 2 - Operation Component Identification (Special Options)
2.6 Component Identification note

(Special Options) When the ignition is turned off, the reserve
The following descriptions are for identification, oil in the accumulator is released to the
explanation and locating purposes only. steer system and may be heard as a
swishing sound as the oil passes through
2.6-1 Main Power Disconnect Switch the system. This is normal.
(If Equipped)
Main Power 2.6-3 Optional Secondary Park Brake

Disconnect (If Equipped)
Switch In addition to the dual service brake and the parking
brake disc on the front axle pinion, telehandler equipped
with these options include a secondary Spring Applied
Hydraulically Released (SAHR) disc brake mounted to
Dual the rear axle pinion.
Batteries
In the event of low service brake pressure, either one,
or both pinion brakes will apply automatically. Also, a
red light indicator on instrument cluster will warn the
operator of low brake pressure.
Figure 2-3 Main Power Disconnect Switch
at rear of telehandler
This switch, when in “ ” off position, disonnects power

to all circuits. Switch must be in “ ” on position to operate
any circuit. Turn switch “ ” off when transporting the
telehandler.
2.6-2 Optional Reserve Steering (If Equipped)

The auxiliary steer system will temporarily maintain the
steering pressure in the event of a engine failure or low
pump output pressure.



When low pump output pressure is detected, a red 
warning light will illuminate on the dash and the




solenoid valve in the reserve steering circuit will open 

 
allowing the reserve oil pressure into the steer system 



to maintain steering control. The telehandler should be 




 
brought to an immediate stop while steering control is  
 
still available.



One-way Reserve Steering Figure 2-5 Reserve Steering &


Directional Valve Accumulator Park Brakes Labels



Figure 2-4 Reserve Steering Accumulator

Under Operator’s Cab
ZB20032
TM

Operator’s Responsibility Section 2 - Operation
2.7 Operator’s Responsibility The operator should make a copy of the Operator’s
It is the responsibility of the operator, prior to each work Checklist (see Table 2.6) and fill out the visual and daily
shift, to perform the following: maintenance inspections and the function tests sections
while performing the items outlined in Section 2.8 and
1. Visual and Daily Maintenance Inspections Section 2.9.
• Designed to discover any damage of components IMPORTANT

before the telehandler is put into service. If telehandler is damaged or any
unauthorized variation from factory-
• Completed before the operator performs the delivered condition is discovered,
function tests. telehandler must be tagged and removed
from service.
WARNING
Repairs to the telehandler may only be made by a
Failure to locate and repair damage, and qualified service technician. After repairs are completed,
discover loose or missing parts may the operator must perform visual and daily maintenance
result in an unsafe operating condition. inspections & function tests again.
2. Function Tests Scheduled maintenance inspections shall only be
performed by a qualified service technician (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.
ZB20032
TM

Section 2 - Operation Visual and Daily Maintenance Inspections
Attachment
2004
4
Operator’s
Cab
2.8 Visual & Daily Maintenance 2.8-2 Electrical

Inspections Maintaining the electrical components is essential to
Before performing the visual and daily maintenance good performance and service life of the telehandler.
inspections, ensure that the telehandler is parked on a
firm level surface. • Ensure proper operation of all gauges
• Check charging system Ammeter/Voltmeter
Begin the visual and daily maintenance inspections • Inspect the following areas for chafed, corroded
by checking each item in sequence for the conditions and loose wires:
listed in this section. • boom wiring harnesses
• frame wiring harnesses
• cab wiring harnesses
WARNING

To avoid injury, do not operate a Ensure electrical devices are properly secured with no
telehandler until all malfunctions have signs of visible damage. Ensure there are no loose or
been corrected. missing parts.
WARNING 2.8-3 Safety Switches

Ensure safety switches are properly secured with no
To avoid possible injury, ensure telehandler signs of visible damage.
power is off during your visual and daily
maintenance inspections. 2.8-4 Mirrors
Ensure mirrors are properly secured with no signs of
Note visible damage.
While performing visual and daily
inspections in different areas, be aware
to also inspect 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.
ZB20032
TM

Visual and Daily Maintenance Inspections Section 2 - Operations
Bottom View
4
04
20
Rear Drive Outriggers

Shaft
Front Axle
2.8-5 Hydraulic -- Check all tire treads and sidewalls for cuts,
Maintaining the hydraulic components is essential to cracks, punctures and unusual wear.
good performance and service life of the telehandler
Perform a visual inspection and check for leaks around -- Check each wheel for damage and cracked
the following areas: welds.
• hydraulic tank, filter(s), fittings, hoses, pump, -- Check each lug nut for proper torque to
and frame surface ensure none are loose.
• all hydraulic cylinders
• all hydraulic manifolds To safeguard maximum stability, achieve optimum
• underside of the frame telehandler handling and minimize tire wear, it is
• ground area under the telehandler essential to maintain proper pressure in all air-
filled tires.
2.8-6 Cylinders
-- Ensure all cylinders are properly secured -- Check each tire with an air pressure gauge
and there is no evidence of leakage. and add air as needed.
-- Grease weekly and check pins and • Drive Axle

bushings to ensure there is no evidence -- Ensure drive axle is properly secured,
of damage. there are no loose or missing parts, all
fittings and hoses are properly tightened
2.8-7 Frame and there is no evidence of oil leakage.
• Wheel/Tire Assembly
The telehandler is either equipped with air • Steer Cylinder Assembly
tires or foam-filled tires. Tire and/or wheel -- Ensure steer cylinder assembly is properly
failure could result in a telehandler tipover. secured, there are no loose or missing
Component damage may also result if parts, all fittings and hoses are properly
problems are not discovered and repaired in tightened and there is no evidence of
a timely fashion. hydraulic oil leakage.
• Steer Linkage
WARNING -- Ensure there are no loose or missing
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.
ZB20032
TM

44
Rear side View 200
Exhaust
System
Rear
Door
Standard
Batteries
• Batteries 5. Replace batteries if damaged or incapable of

Proper battery condition is essential to good holding a lasting charge.
engine performance and operational safety.
Improper fluid levels or damaged cables and WARNING
connections can result in engine component
damage and hazardous conditions. Use original or manufacturer-approved
parts and components for the
telehandler.
WARNING
Explosion hazard. Keep flames
and sparks away. Do not smoke • Engine Air Filter
near batteries. -- Ensure there are no loose or missing
parts and there is no visible damage.
WARNING -- Ensure air cleaner vaccuator valve (if

applicable) is free from dirt or dust by
Battery acid is extremely corrosive -
squeezing the valve lips.
Wear proper eye and facial protection as
well as appropriate protective clothing. • Engine Coolant
If contact occurs, immediately flush with -- The coolant level should be between
cold water and seek medical attention. the minimum and maximum marks.
Add coolant as needed. Refer to your
1. Check batteries case for damage. engine manual for recommended coolant
mixture.
2. Clean terminals and cable ends thoroughly
with a terminal cleaning tool or wire brush. • Muffler and Exhaust
-- Ensure muffler and exhaust systems are
3. Ensure all connections are tight. properly secured, with no evidence of
damage.
4. If applicable, check battery fluid level. If plates
are not covered, add distilled or demineralized
water.
ZB20032
TM

Exhaust
Engine
Compartment
Rear Axle
& Tire
2.8-8 Engine Compartment

-- Ensure compartment cover is secure and in Perform a visual inspection around the following
proper working order. areas:
• hoses and fittings
• Engine Oil Level • fuel pump
-- Maintaining the engine components • fuel filter
is essential to good performance and • fuel tank
service life of the telehandler.
• Hydraulic Pumps
WARNING
-- Ensure there are no loose or missing
Beware of hot engine components. parts and there is no visible damage.
Check oil level on dipstick -- Ensure all bolts are properly tightened.
-- Oil level should be in the “safe” zone. -- Ensure all fittings and hoses are properly
Add oil as needed. Refer to Table 2.4 for tightened and there is no evidence of
recommended oil type. hydraulic oil leakage.
• Fuel Leaks • Belts
Failure to detect and correct fuel leaks will -- Ensure belts are in good working
result in an unsafe condition. An explosion or condition and have correct tension.
fuel fire may cause death or serious injury. Replace if belts are cracked, frayed, or
have chunks of material missing. Refer to
DANGER engine manufacturer’s manual 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.
ZB20032
TM

44
200
Hydraulic Oil Fuel Tank

Tank
• Fuel Tank • Hydraulic Return Filter

-- Ensure filter element is secure.
IMPORTANT
Before using your telehandler ensure -- Ensure there are no signs of leakage or
there is enough fuel for expected use. visible damage.
-- Ensure fuel filler cap is secure. 2.8-9 Transmission

-- Ensure tank shows no visible damage -- Ensure transmission shifter is working properly
and no evidence of fuel leakage. and there is no evidence of damage.
• Hydraulic Tank • Check oil level on dipstick

-- Ensure hydraulic filler cap is secure. -- Oil level should be in the “safe” zone.
Add oil as needed. Refer to Table 2.4 for
-- Ensure tank shows no visible damage recommended oil type.
and no evidence of hydraulic leakage.
• Hydraulic Oil
-- Be sure that the boom is in the stowed
position, 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. Refer to
Table 2.4 for recommended oil type.
ZB20032
TM

Boom Assembly
20
04
4
Lifting Attachment Boom Extend

Cylinder
2.8-10 Boom 2.8-11 Lifting Attachment

-- Ensure there are no loose or missing parts -- Ensure there are no loose or missing parts
and there is no visible damage. and there is no visible damage.
-- Ensure all bolts and pins are properly -- Ensure attachment is properly positioned
tightened. and secured. (refer to Section 2.15 for
attachments)
-- Ensure there are no visible cracks in welds
or structure and there are no signs of
deformation. 2.8-12 Grease Points
Maintaining properly greased components is essential
-- Ensure all hoses are properly tightened and for good performance and service life of the telehandler.
there is no evidence of hydraulic leakage. If components are improperly greased, it could result
• Slide Pads in component damage.
-- Ensure all bolts are tight, there is no
visible damage to the slide pads and that
WARNING
no parts are missing.
Ensure that there are no personnel or
• Chain obstructions in maintenance area.
-- Ensure there are no loose or missing
parts and there is no visible damage Greasing intervals are based on telehandler usage
of 40 hours. Use of telehandler may vary significantly
• Boom Angle Indicator and greasing frequency must be adjusted to obtain
-- Ensure all bolts are tight, and there is no maximum service life.
visible damage
Refer to service manual for complete list of grease points
locations and greasing schedule.
Refer to Table 2.4 for recommended fluids and

lubricants.
ZB20032
TM

Axle Grease
Points
Grease Points on Frame Grease Points on Boom Assembly

1. Ensure telehandler is on a firm level surface 1. Ensure telehandler is on a firm level surface
and is in stowed position. and is in stowed position.
2. Locate grease fittings (refer to label inside 2. Locate grease fittings (refer to label inside
operator’s cab) and pump grease in the operator’s cab) and pump grease in the
following: following:
-- axle pivot bearings (front and rear) -- main boom pivot bearing pins
-- axle lock cylinder (top and bottom) -- retract chain rollers
-- lift cylinder (top and bottom, both -- hose rollers
sides)
-- extension chains and rollers
-- frame level cylinders (top and bottom)
-- slide pads
-- outrigger pins
-- attachment tilt cylinders (top and
-- slave cylinders (top and bottom) bottom)
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)
ZB20032
TM

Operator’s Cab
WARNING
Steering DEC-016
Wheel
Controllers
Console
ELECTROCUTION 5 1
HAZARD
21
EVERY 40 HRS
OF SERVICE UNLESS
PSI
NOTED
1
KEEP CLEAR
CLEAN AND OIL
BRAKE PEDAL
2 PIVOT PIN
GREASE AXLE
10 4 PLS
RESULT FROM 1. STOP
PLS
IF THEY BECOME OR 2. RAISE LOAD
BOTH SIDES 2 BOOM PIVOT BEARING PINS
LOCK CYLINDER
DEC-002 6 TOP & BTM
6 8 GREASE AXLE
7
22
PSI
PLS
4
7 GREASE SLIP JOINT
14 PLS
18 8 GREASE DRIVE
PLS
12 9 GREASE FRAME
BOTH CYLINDERS
11
PINS
15 11 GREASE SLAVE
BOTH CYLINDERS
12 GREASE CARRIAGE
13 BOTH CYLINDERS
13 GREASE CARRIAGE
PIVOT BEARINGS
14 GREASE EXTENSION
9 CHAIN AND ROLLER
3 PLS
LIGHTS
7. TILT FORKS DOWN 11 15 GREASE SLIDE
CHAIN ROLLERS
INSTRUCTIONS
TO SIGNAL MEN 17 GREASE HOSE 3 PLS
1. Only one person ROLLERS 2 PLS
to be signalman
2. Make sure the 3. Signalman must 18 OIL EXTENSION
operator can see
you
10 OF SERVICE
signal given the 4. Never raise or PSI 19 CHECK TORQUE
3
DEC-024 65-70 PSI
ACCUMULATOR
475-500 PSI, EVERY
6 MONTHS
DEC-302





 
The

 



 

Reach

 


 



Machine
K
JOYSTIC
ON FORWARD
3 FUNCTIHOLD
TILT
AND TILT
PUSH FORK
FORK
BACK
FOR
LOWER
BOOM
BOOM
EXTEND
DEC-142
BOOM
RETRACT RAISE
BOOM
FRAME
LEVEL
EL
T F G I R
DEC-055
TH
Brake Pedal
CHECK DAILY
OPERATING
on Forks
for Road Travel
Brake ONLY
Rated Lifting
:Wheel Studs/
Nuts
- Inspect Lift
Drive
and Welded
to ensure Proper
BRAKES: TRAVELLING:
:Pedal Response
Tilted Back to
Forks Height
Ammeter/Voltmeter
1. Apply Park
Brake
in "NEUTRAL"
on Flat, Level
Freezing
WORK SAFETY:
TIRES:
punctures any time
Control Levers
- Thoroughly
Operator Manual
before Operating
"SPECIALISTS
IN ROUGH TERRAIN
FORKLIFTS"
2.8-13 Operator’s Cab -- Always return manual to the manual

storage box after use.
• Rollover and Falling Object Protective
Structure (ROPS/FOPS) • Operator’s Cab Controls
-- Ensure there is no visible damage.
WARNING
WARNING Ensure that you maintain three points of
Do not modify, drill or alter the operator’s contact to mount/dismount the cab.
cab in any way.
Use the steps of telehandler to access operator’s
• Seat cab.
-- Ensure seat is properly secured with no
sign of visible damage. -- Ensure door and windows (if equipped)
are secure and in proper working order.
-- Ensure seat belt is working properly with
no sign of visible damage. -- Ensure steering wheel is secured with no
sign of visible damage.
• Pedals
-- Ensure brake and accelerator pedals are -- Ensure all switches and controls are
secure, no loose or missing parts, no sign properly secured with no sign of visible
of visible damage and movements are damage.
not obstructed.
-- Ensure all switches and controls are
• Manual returned to their neutral positions and
-- Check to be sure manual storage box is movements are not obstructed.
present and in good condition.
-- Ensure capacity charts are in place and
-- Ensure a copy of operating manual, are legible.
and other important documentation are
enclosed in manual storage box. danger
-- Ensure manual is legible and in good Do not operate the telehandler if capacity
condition. charts are missing or not legible.
ZB20032
TM

Section 2 - Operation Function Tests
Boom Joystick Frame Level/Optional

Attachment Joystick
WARNING
Ignition
DEC-016
Switch
ELECTROCUTION 5 1
HAZARD
21
EVERY 40 HRS
OF SERVICE UNLESS
PSI
NOTED
1
KEEP CLEAR
CLEAN AND OIL
BRAKE PEDAL
2 PIVOT PIN
GREASE AXLE
10 4 PLS
RESULT FROM PLS
LOAD, MACHINE 1. STOP 4 GREASE MAIN
IF THEY BECOME OR 2. RAISE LOAD BOTH SIDES 2 BOOM PIVOT BEARING PINS
LOCK CYLINDER
DEC-002 6 TOP & BTM
6 8 GREASE AXLE
7
22
PSI
PLS
4
7 GREASE SLIP JOINT
14 PLS
18 8 GREASE DRIVE
PLS
12 9 GREASE FRAME
5. TILT FORKS LEFT 11 3
BOTH CYLINDERS
PINS
15 11 GREASE SLAVE
BOTH CYLINDERS
12 GREASE CARRIAGE
13 BOTH CYLINDERS
13 GREASE CARRIAGE
PIVOT BEARINGS
14 GREASE EXTENSION
9 CHAIN AND ROLLER
3 PLS
LIGHTS
CHAIN ROLLERS
INSTRUCTIONS 17 GREASE HOSE 3 PLS
1. Only one person TO SIGNAL MEN ROLLERS 2 PLS
to be signalman
operator can see
you
10 OF SERVICE
workmen, warn
lower the load over
other
3
20 DAILY FOR FIRST ON WHEEL LUG NUTS
DEC-024 65-70 PSI
MANUALS FOR AND OPERATOR'S
6 MONTHS
ACCUMULATOR
475-500 PSI, EVERY PRESSURE
INFORMATION. 6 MONTHS
DEC-302
The
Reach
Machine
K
JOYSTIC
ON FORWARD
3 FUNCTIHOLD
TILT
AND TILT
PUSH FORK
FORK
BACK
FOR
LOWER
BOOM
BOOM
EXTEND
DEC-142
BOOM
RETRACT RAISE
BOOM
FRAME
LEVEL
EL
T F G I R
DEC-055
TH
Joystick
Controller
CHECK DAILY
GENERAL:
AXLES:
BRAKES:
ELECTRICAL:
:Hydraulic Cylinders
:Radiator and
:Transmission
:Oil Leaks at
battery level
:Hydraulic Hoses
:Mounting Bolts
:Wheel Studs/
:Pedal Response
:Clean Mud and
:All Exposed
and Fittings
Fluid, Hydraulic
Nuts
Drive
Oil
:Two Wheel Drive Hubs and Differential

Units Only--Steer
Debris from Brake
Wiring
:Proper Operation
Pedal Assembly
OPERATING
- Centre Load
- Observe All
- Bring Unit to
- Use High Gear
- Disengage Park
- Never Exceed
- Inspect Lift
Components
- Cycle Each
Operation
TRAVELLING:
INSTRUCTIONS:
on Forks
- Beware of Overhead
Obstacles
Operating and
Component( Mast
Safety Decals
a Full Stop Before
for Road Travel
Brake
Rated Lifting
- Feather Hydraulic
Hydraulic Function
- Keep Telescopic
- Keep Carriage
- Always Have
Booms Fully
Tilted Back to
- Travel with Load
on Machine
Changing Direction
of Unloaded Unit
Capacity -- See
Controls when
or Boom ) Chains,
at Start of Day
Retracted
Avoid
Forks Height
- Travel in Reverse Pointed Up Hill on a Grade
if Load Obstructs
Forward Vision
ONLY
Factory
Nearing Maximum Load Chart
Mast/Boom Extension
Rollers, Pins
to ensure Proper
and Welded
Console
Ammeter/Voltmeter
1. Apply Park
Brake
in "NEUTRAL"
on Flat, Level
Freezing
WORK SAFETY:
TIRES:
punctures any time
Control Levers
- Thoroughly
Operator Manual
before Operating
"SPECIALISTS
IN ROUGH TERRAIN
FORKLIFTS"
2.9 Function Tests 2.9-1 Operator’s Cab Controls

Function tests are designed to discover any malfunctions
before telehandler is put into service. The operator must WARNING
understand and follow step-by-step instructions to test
all telehandler functions. Ensure that you maintain three points of
contact to mount/dismount the cab.
IMPORTANT
Never use a malfunctioning telehandler. If • Test Starter Operation
malfunctions are discovered, telehandler
must be tagged and placed out of service. 1. Enter cab and close door (if equipped).
Repairs to telehandler may only be made
by a qualified service technician. WARNING
The seat belt must be worn at all times.
After repairs are completed, operator must perform a
pre-operation inspection and a series of function tests 2. Sit in the driver’s seat and fasten seat
again before putting telehandler into service. belt.
Prior to performing function tests, be sure to read and 3. Using a spotter, adjust the mirrors.
understand Section 2.10 - Start Operation.
4. Ensure parking brake is engaged.
WARNING
Ensure that there are no personnel or 5. Adjust the boom controller console.
obstructions in test area and that there
is sufficient room to test all telehandler
functions.
ZB20032
TM

Function Tests Section 2 - Operation
Transmission
Lever
IMPORTANT
WARNING WARNING
WARNING WARNING
No Riders
DEC-013A
DEC-099 DEC-100
Extending ourselves
for you.







DANGER
20044

 
 
 
DO NOT OPERATE
 
THIS MACHINE  
WITHOUT SEAT  
 
BELT FASTENED  
DEC-023

IMPORTANT 

MPORTANT



DEC-022

DEC-320
ALL TURBO-ENGINES
DEC-322
BRAKE ACTUATED
TRANSMISSION
LEFT RIGHT
HORN
NORMAL
LEFT RIGHT
TRANSMISSION FRONT
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
DEC-216
Right Turn Horn Push

Signal Switch Button
6. Insert key into ignition switch and select • Test Lights (If Equipped)
“ ” on position. The red and amber lights
at the top of electronic dash display will 1. Use a spotter to check if all the lights are
illuminate. Once red and amber lights are working well. The spotter should maintain
no longer displayed, and the electronic a safe distance from telehandler.
gauges are visible on the display panel;
turn the key to start position. 2. Turn parking brake switch to off position.
Result: Rear brake lights should turn off.
7. Allow engine to idle for 30 seconds until
low brake pressure light is off. 3. Depress service brake pedal.
Result: Rear brake lights should turn
• Test Horn on.
1. Push “ ” horn push-button. 4. Select head/tail light (if equipped) switch

Result: Horn should sound. to on position.
Result: Head/tail lights should turn on.
WARNING 5. Turn parking brake switch to on position.
If the warning indicator lights illuminate
when engine is running, immediately 6. Select left turn signal (if equipped) rocker
shut down the telehandler and have it switch to on position.
serviced. Result: The left signal light should flash.
• Test Reverse Alarm 7. Select right turn signal (if equipped) rocker
switch to on position.
1. Ensure parking brake switch is on. Result: The right signal light should
flash.
2. Depress service brake pedal and shift the
transmission lever backward.
Result: The reverse alarm should sound
and reverse light (if equipped) should turn
on.
ZB20032
TM

Boom Joystick Frame Level/Optional

Attachment Joystick
WARNING
Ignition
DEC-016
Switch
ELECTROCUTION 5 1
HAZARD
21
EVERY 40 HRS
OF SERVICE UNLESS
PSI
NOTED
1
KEEP CLEAR
CLEAN AND OIL
BRAKE PEDAL
2 PIVOT PIN
GREASE AXLE
10 4 PLS
RESULT FROM PLS
LOAD, MACHINE 1. STOP 4 GREASE MAIN
LOCK CYLINDER
DEC-002 6 TOP & BTM
6 8 GREASE AXLE
7
22
PSI
PLS
4
7 GREASE SLIP JOINT
14 PLS
18 8 GREASE DRIVE
PLS
12 9 GREASE FRAME
5. TILT FORKS LEFT 11 3
BOTH CYLINDERS
PINS
15 11 GREASE SLAVE
BOTH CYLINDERS
12 GREASE CARRIAGE
13 BOTH CYLINDERS
13 GREASE CARRIAGE
PIVOT BEARINGS
14 GREASE EXTENSION
9 CHAIN AND ROLLER
3 PLS
LIGHTS
CHAIN ROLLERS
to be signalman
operator can see
you
10 OF SERVICE
workmen, warn
lower the load over
other
3
DEC-024 65-70 PSI
6 MONTHS
ACCUMULATOR
DEC-302
The
Reach
Machine
K
JOYSTIC
ON FORWARD
3 FUNCTIHOLD
TILT
AND TILT
PUSH FORK
FORK
BACK
FOR
LOWER
BOOM
BOOM
EXTEND
DEC-142
BOOM
RETRACT RAISE
BOOM
FRAME
LEVEL
EL
T F G I R
DEC-055
TH
Joystick
Controller
CHECK DAILY
GENERAL:
AXLES:
BRAKES:
ELECTRICAL:
:Radiator and
:Transmission
:Oil Leaks at
battery level
:Hydraulic Hoses
:Mounting Bolts
:Wheel Studs/
:Pedal Response
:Clean Mud and
:All Exposed
and Fittings
Fluid, Hydraulic
Nuts
Drive
Oil

Units Only--Steer
Debris from Brake
Wiring
:Proper Operation
Pedal Assembly
OPERATING
- Centre Load
- Observe All
- Bring Unit to
- Use High Gear
- Disengage Park
- Never Exceed
- Inspect Lift
Components
- Cycle Each
Operation
TRAVELLING:
INSTRUCTIONS:
on Forks
Obstacles
Operating and
Component( Mast
Safety Decals
a Full Stop Before
for Road Travel
Brake
Rated Lifting
- Feather Hydraulic
Hydraulic Function
- Keep Telescopic
- Keep Carriage
- Always Have
Booms Fully
Tilted Back to
- Travel with Load
on Machine
Changing Direction
of Unloaded Unit
Capacity -- See
Controls when
or Boom ) Chains,
at Start of Day
Retracted
Avoid
Forks Height
if Load Obstructs
Forward Vision
ONLY
Factory
Mast/Boom Extension
Rollers, Pins
to ensure Proper
and Welded
Console
Ammeter/Voltmeter
1. Apply Park
Brake
in "NEUTRAL"
on Flat, Level
Freezing
WORK SAFETY:
TIRES:
punctures any time
Control Levers
- Thoroughly
Operator Manual
before Operating
"SPECIALISTS
IN ROUGH TERRAIN
FORKLIFTS"
• Test Boom and Attachment Functions 4. Tilt attachment forward by pressing and
holding the thumb button while moving
WARNING joystick forward.
Result: Attachment should tilt forward.
obstructions in test area and that there 5. Tilt attachment backward by pressing and
is sufficient room to test all telehandler holding the thumb button while moving
functions. joystick backward.
Result: Attachment should tilt backward.
1. Ensure the parking brake indicator light is
on. 6. Retract the boom by moving the boom/
attachment joystick to the left.
2. Raise the boom by pulling the boom/ Result: Boom should retract.
attachment joystick backward.
Result: Boom should raise and boom 7. Lower the boom by moving the boom/
angle indicator should be functioning. attachment joystick forward.
Result: Boom should lower.
3. Extend the boom by moving the boom/
attachment joystick to the right. 8. Raise the boom until attachment is 2 feet
Result: Boom should extend and boom above the ground.
extension indicators are visible.
important
Test all attachment functions if telehandler
is equipped with optional attachments.
Refer to Section 2.15 for optional
attachments operation.
ZB20032
TM

WARNING
IMPORTANT
WARNING WARNING
WARNING WARNING
DEC-016

No Riders
DEC-013A
DEC-099 DEC-100
Extending ourselves
for you.
Frame level







DANGER
20044

 
Indicator
 
DO NOT OPERATE  
 
THIS MACHINE  
WITHOUT SEAT  
 
BELT FASTENED  
DEC-023

DANGER FORKLIFT SIGNALS
MPORTANT
ZB10044/10056
IMPORTANT 

ELECTROCUTION
HAZARD
KEEP CLEAR
21
PSI
5 1
EVERY 40 HRS
1
2
OF SERVICE UNLESS
CLEAN AND OIL
GREASE AXLE
BRAKE PEDAL

NOTED
PIVOT PIN

10 4 PLS
RESULT FROM 1. STOP
PLS

FIRST 150 HOURS OPERATION

LOCK CYLINDER
DEC-002 6 TOP & BTM
GREASE AXLE

6 8
7
22
PSI
PLS
4
7 GREASE SLIP JOINT
ON DRIVE SHAFT

17 15 15 FRNT & REAR 2
PLS
2. CHECK AXLE & SPRING

14
18 8 GREASE DRIVE
 4. TILT FORKS RIGHT
12 9
PLS
GREASE FRAME
TOP & BOTTOM, LEVEL CYLINDER
5. TILT FORKS LEFT BOTH CYLINDERS

11 3
PINS
15 11 GREASE SLAVE
BOTH CYLINDERS
12 GREASE CARRIAGE
13 BOTH CYLINDERS
13 GREASE CARRIAGE
DEC-022 9
14 GREASE EXTENSION
PIVOT BEARINGS
CHAIN AND ROLLER
3 PLS
LIGHTS
CHAIN ROLLERS
to be signalman
operator can see
you
10 OF SERVICE
workmen, warn
lower the load over
other
3
DEC-024 65-70 PSI
6 MONTHS
ACCUMULATOR
PARK AXLE DIFF CHARGE DEC-302

DEC-320
ALL TURBO-ENGINES 
AIR CLEANER AND EXHAUST 







The

TRANSPORT DEC-052
 
TO INITIALIZE, THEN START ENGINE. 





Reach
DEC-322 
 


BRAKE ACTUATED
STEERING PARKING OUTRIGGERS TURN SIGNALS

SECONDARY
HORN


TRANSMISSION

BRAKE LEFT RIGHT e

Machin
DISCONNECT BRAKE DEC-308E
NORMAL
LEFT RIGHT JOYSTICK
ROUND ON ON DOWN DOWN

FORWARD
3 FUNCTION
ON ON HOLD
TILT
OPERATION FORK
AND TILT
PUSH FORK BACK
FOR
LOWER
BOOM
BOOM
EXTEND
DEC-142
BOOM
RETRACT RAISE
BOOM
TRANSMISSION FRONT
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
DEC-216
FRAME
LEVEL
EL
T F G I R
DEC-055
TH
Axle Lock
Light CHECK DAILY
GENERAL:
AXLES:
BRAKES:
ELECTRICAL:
ENGINE:
:Radiator and
battery level
:Hydraulic Hoses
:Transmission
:Mounting Bolts
:Wheel Studs/
:Oil Leaks at
:Pedal Response
:Clean Mud and
:All Exposed
:Hoses
:Belts
and Fittings
Fluid, Hydraulic
Nuts
Drive
Wiring
:Proper Operation
Oil

Units Only--Steer
Debris from Brake
:Charging System of All Gauges
:Fluid Levels/
Pedal Assembly
Ammeter/Voltmeter
Leaks
OPERATING
- Centre Load
- Observe All
- Bring Unit to
- Use High Gear
- Disengage Park
- Never Exceed
- Inspect Lift
Components
- Cycle Each
Operation
TRAVELLING:
- Keep Carriage
- Always Have
INSTRUCTIONS:
on Forks
Obstacles
Operating and
Safety Decals
a Full Stop Before
for Road Travel
Brake
Rated Lifting
- Feather Hydraulic
Component( Mast
Hydraulic Function
- Keep Telescopic
PARKING PROCEDURE:
1. Apply Park
Brake
2. Place Transmission
3. Park Machine
4. Park Machine
in Mud during
WORK SAFETY:
on Machine
Changing Direction
of Unloaded Unit
Capacity -- See
Controls when
at Start of Day
Booms Fully Retracted

Tilted Back to
Forks
if Load Obstructs
in "NEUTRAL"
on Flat, Level
Height
ONLY
Factory
or Boom ) Chains, Mast/Boom Extension
Rollers, Pins
to ensure Proper
Forward Vision
Surface or Chock
Winter Operation Clear of Ground to Avoid
Freezing
and Welded
Parking Brake
TIRES:
punctures any time
Control Levers
Parking Brake
- Thoroughly
Operator Manual
before Operating
"SPECIALISTS
IN ROUGH TERRAIN
FORKLIFTS"
Switch Indicator Light

Brake Pedal Accelerator
Pedal
• Te s t F r a m e L e v e l i n g a n d L e v e l • Test Rear Axle Lock

Indicator
1. Ensure parking brake switch is on.
2. Raise boom above 45° - boom angle and
2. Tilt frame to the right by moving frame level attempt leveling the frame to the right or
joystick to the right. to the left.
Result: Frame should tilt to the right. Result: Rear axle lock light should
illuminate and frame should not tilt to right
3. Tilt frame to the left by moving frame level or left.
joystick to the left.
Result: Frame should tilt to the left. 3. Lower the boom until attachment is 2 feet
above the ground.
4. Use the frame level indicator to ensure
frame is level. • Test Accelerator Pedal
2. Depress accelerator pedal slowly.

Result: The engine RPM should
increase.
3. Release the accelerator pedal.

Result: The engine RPM should
decrease.
ZB20032
TM

Transmission Lever
IMPORTANT
WARNING WARNING
WARNING WARNING
No Riders
DEC-013A
DEC-099 DEC-100
Extending ourselves
for you.







DANGER
20044

 
 
 
DO NOT OPERATE
 
THIS MACHINE  
WITHOUT SEAT  
 
BELT FASTENED  
DEC-023

IMPORTANT 

MPORTANT



DEC-022

DEC-320
ALL TURBO-ENGINES
TRANSPORT DEC-052
TO INITIALIZE, THEN START ENGINE.
DEC-322
BRAKE ACTUATED
TRANSMISSION
LEFT RIGHT
HORN
NORMAL
LEFT RIGHT
TRANSMISSION FRONT
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
DEC-216
Steering
Selector Switch Ignition Switch
• Test Driving & Service Brake Functions • Test Steering
1. Ensure path of intended motion is clear. CAUTION
2. Ensure all four wheels are aligned straight Before changing steering modes, bring
ahead. all four wheels into alignment (i.e., in the
straight-ahead position).
3. Depress service brake pedal.
WARNING
4. Release parking brake.
Before driving on public roads and
Result: Parking brake indicator light
highways check the alignment of the
should turn off.
wheels and drive with FRONT steering
only.
5. Shift transmission lever forward and
release the service brake pedal slowly.
Result: Telehandler should move WARNING
forward. Do not change steer mode while
telehandler is traveling.
6. Depress service brake pedal slowly.
Result: Telehandler should stop. Note
Avoid steering the wheels while telehandler
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.
ZB20032
TM

Steering Wheel
Hour Meter
IMPORTANT
WARNING WARNING
Front Display
WARNING WARNING
Panel
No Riders
DEC-013A
DEC-099 DEC-100
Transmission Extending ourselves

for you.
Lever 






DANGER
20044

 
 
 
DO NOT OPERATE
 
THIS MACHINE  
WITHOUT SEAT  
 
BELT FASTENED  
DEC-023

IMPORTANT 

MPORTANT



DEC-022

DEC-320
ALL TURBO-ENGINES
DEC-322
BRAKE ACTUATED
TRANSMISSION
LEFT RIGHT
HORN
NORMAL
LEFT RIGHT
FRONT
Steering
TRANSMISSION
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
DEC-216
Selector Switch
Round Steer 6. Steer the telehandler straight ahead until

all four wheels are aligned.
7. Depress service brake pedal until the

telehandler stops.
Front Steer
Figure 2-6 Round Steering
1. Ensure path of intended motion is clear.
2. Ensure all four wheels are aligned straight

ahead.
Figure 2-7 Front Steering
3. Select parking brake switch to off position
and depress service brake pedal. 8. Select rocker switch to middle “ ”
position for front steering.
4. Select rocker switch to forward “ ”
9. Turn the steering wheel to the left or right
position for round steering.
and drive forward.
Result: Only front wheels of the telehandler
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.
ZB20032
TM

Hour Meter Steering Wheel
IMPORTANT
WARNING WARNING WARNING WARNING

Front Display
Transmission Panel
No Riders
DEC-013A
DEC-099 DEC-100
Lever Extending ourselves

for you.







DANGER
20044

 
 
DO NOT OPERATE  
 
THIS MACHINE  
WITHOUT SEAT  
 
BELT FASTENED  
DEC-023

IMPORTANT 

MPORTANT



DEC-022

DEC-320
ALL TURBO-ENGINES
TRANSPORT DEC-052
DEC-322
BRAKE ACTUATED
TRANSMISSION
LEFT RIGHT
HORN
NORMAL
LEFT RIGHT
ROUND ON ON DOWN DOWN ON ON
Steering
OPERATION
TRANSMISSION FRONT
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
DEC-216
Selector Switch
10. Steer the telehandler straight ahead until 13. Turn the steering wheel to the left or right
all four wheels are aligned. and drive forward.
Result: Telehandler should move in the
11. Depress service brake pedal until the chosen direction with both front and rear
telehandler stops. wheels in the same direction.
Crab Steer 14. Steer the telehandler straight ahead until

all four wheels are aligned.
15. Depress service brake pedal until the

telehandler stops.
Figure 2-8 Crab Steering
12. Select rocker switch to backward “ ”

position for crab steering.
ZB20032
TM

Steering Wheel
IMPORTANT
WARNING WARNING
WARNING WARNING
No Riders
DEC-013A
DEC-099 DEC-100
Extending ourselves
for you.







DANGER
20044

 
 
DO NOT OPERATE  
 
THIS MACHINE  
WITHOUT SEAT  
 
BELT FASTENED  
DEC-023

IMPORTANT 

MPORTANT



DEC-022

DEC-320
ALL TURBO-ENGINES
DEC-322
BRAKE ACTUATED
TRANSMISSION
LEFT RIGHT
HORN
NORMAL
LEFT RIGHT
TRANSMISSION FRONT
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
DEC-216
Parking Brake Outriggers

Switch Switches
• Test Parking Brake • Test Outriggers (If Equipped)
Caution WARNING
Refer to Section 2.10-3 for instructions Ensure that there are no personnel or
on how to drive on a slope. obstructions in test area and that there
is sufficient room to test all telehandler
1. Ensure path of intended motion is clear. functions.
2. Ensure parking brake switch is off. 1. Ensure parking brake switch is on.
3. Drive the telehandler on a slope. 2. Lower outriggers by depressing and

holding rocker switch forward “ ”
4. Depress service brake pedal slowly until continuously.
telehandler stops. Result: Outriggers should lower.
5. Select parking brake rocker switch to 3. Raise outriggers by depressing and

on position and release service brake holding rocker switch backward
pedal. “ ” continuously until outriggers are
Result: Parking brake indicator light fully raised.
should turn on and telehandler should not Result: Outriggers should raise up.
roll
ZB20032
TM

Hour Meter Steering Wheel
IMPORTANT
WARNING WARNING WARNING WARNING

Front Display
Transmission Panel
No Riders
DEC-013A
DEC-099 DEC-100
Lever Extending ourselves

for you.







DANGER
20044

 
 
DO NOT OPERATE  
 
THIS MACHINE  
WITHOUT SEAT  
 
BELT FASTENED  
DEC-023

IMPORTANT 

MPORTANT



DEC-022

DEC-320
ALL TURBO-ENGINES
TRANSPORT DEC-052
DEC-322
BRAKE ACTUATED
TRANSMISSION
LEFT RIGHT
HORN
NORMAL
LEFT RIGHT
ROUND ON ON DOWN DOWN ON ON
Steering
OPERATION
TRANSMISSION FRONT
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
DEC-216
Selector Switch
Secondary Brake
Activation Switch
• Test Optional Reserve Steering • Test Secondary Park Brake

(If Equipped) (If Equipped)
1. Start engine and let it run for approximately Caution

2 minutes to ensure proper charging of
reserve steering accumulator. Refer to Section 2.10-3 for instructions
on how to drive on a slope.
Note
At initial start up, the red steer light should 1. Ensure path of intended motion is clear.
light momentarily and then go out.
2. Ensure both park and secondary park
2. Turn off engine. brake switches are off.
3. With ignition key switch in “ ” on position, 3. Drive the telehandler on a slope.

turn steering wheel left and right from lock
to lock position. 4. Depress service brake pedal slowly until
Result: Steering wheel should turn from telehandler stops.
lock to lock. Reserve steering system is
operational. 5. Select secondary brake rocker switch
to on position and release service brake
4. If steering wheel does not fully turn from pedal.
lock to lock, system must be checked Result: Secondary park brake indicator
immediately for accumulator charge light should turn on and telehandler
pressure, system leaks or proper charge should not roll.
solenoid operation.
WARNING
If the pressure in either of the dual
service brake systems fails, charge
pressure light will turn on. The Spring
Applied Hydraulically Released brake
on the system that failed will engage to
bring the telehandler to a full stop.
ZB20032
TM

Start Operation Section 2 - Operation
2.10 Start Operation • has been tagged or blocked out for non-use or
Carefully read and completely understand the Operating repair.
Manual and all warnings and instruction labels on the
telehandler (refer to labels section). Failure to avoid these hazards could
WARNING
2.10-1 Starting the Engine
DO NOT operate this telehandler without
proper authorization and training. Failure
WARNING
to avoid this hazard could result in death
or serious injury. Ensure that you maintain three points of
contact to mount/dismount the cab.
Before operating this telehandler, perform the following
steps: 1. Enter cab and close door (if equipped).
1. Visual and daily maintenance inspections 2. Sit in the driver’s seat and fasten seat belt.
(see Section 2.8)
2. Function tests (see Section 2.9) WARNING
3. Jobsite inspection The seat belt must be worn at all times.
It is the responsibility of the operator to perform
a jobsite inspection and avoid the following 3. Ensure parking brake is on and gear selector in
hazardous situations: neutral position.
• holes or drop-offs 4. To start the engine, turn the ignition switch to on

• ditches or soft fills position. The red and amber lights at the top of
• floor obstructions, bumps or debris electronic dash display will illuminate. Once red
• overhead obstructions and amber lights are no longer displayed, and the
• electrical cords, hoses and high voltage electronic gauges are visible on the display panel;
conductors turn key to start position.
• hazardous locations
• inadequate surface support to withstand all 5. Allow engine to idle for 30 seconds until low brake
load forces imposed by the telehandler pressure light is off.
• wind and weather conditions
• the presence of 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
missing parts.
• has alterations or modifications not approved by
the manufacturer.
• has safety devices which have been altered or
disabled.
ZB20032
TM

Section 2 - Operation Start Operation
2.10-2 Driving the Telehandler 2.10-3 Driving on Slopes
NOTE DANger
• Be aware of blind spots when operating the
telehandler. Driving on slopes or inclines can be
• Ensure that there are no personnel or obstructions dangerous and result in forklift tipover
in the path of travel, including blind spots. or loss of load.
• When traveling at high rate of speed, use front
wheel steering mode. WARNING
• Slow the telehandler prior to turning.
• Always look at the direction of travel.
• Avoid excessively steep slopes or unstable
• Travel in reverse only at slow rate of speed.
surfaces. Do not drive across excessively steep
Drive only as fast as condition allows.
slopes under any circumstances.
• Keep attachment or load low (18 - 24 inches) to
• Avoid turning on slopes, if at all possible.
the ground which gives the best visibility and
stability.
1. Keep load low and proceed with caution.
• Ensure outriggers (if equipped) are fully raised
before driving.
2. Reduce travel speed and downshift to a lower gear
before reaching a slope.
The telehandler is equipped with a powershift
transmission. The transmission has forward and reverse
3. Ascend and descend slopes with the “heavy end”
gears with speed ranges available in both directions.
of the telehandler pointing up the slope.
1. Depress service brake pedal and move transmission
NOTE
control lever to the desired direction of travel.
When the telehandler has no load, the rear
is considered the “heavy end.” Travel with
2. Release parking brake.
the attachment pointed downhill.
3. Begin selecting first gear and slowly release
When the telehandler is carrying a load,
service brake pedal.
the front is considered the “heavy end.”
Travel with the attachment pointed uphill.
4. Depress accelerator pedal slowly to increase
speed. Twist the transmission hand grip to select
4. When driving across a slope, keep frame level.
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,
or slopes. Select higher gears only when traveling
long distances on smooth terrain without a load.
6. Always bring the telehandler to a complete stop

before changing the direction of travel.
Figure 2-9 Driving on Slopes
ZB20032
TM

2.10-4 Steering the Telehandler Crab Steer

Steering is controlled by means of the steering wheel The crab steer is used for maneuvering into tight
in conjunction with the steering mode selector rocker spots.
switch for the type of steering desired.
Round Steer
This steer mode is most commonly used on the job site
and will give the smallest turn radius available.
Figure 2-12 Crab Steering
2.10-5 Leveling the Telehandler

Figure 2-10 Round Steering
1. To level frame to the right, move frame level
joystick to the right. To level frame to the left, move
Front Steer frame level joystick to the left.
Two-wheel steer is used during road travel in order
to reduce the risk of possible overturn due to 2. Release joystick to stop.
over-steering.
NOTE 2.10-6 Raising or Lowering Boom

Loss of electrical power will allow front
steering only. WARNING
obstructions and there is sufficient room
to perform all telehandler functions.
1. To raise the boom, pull boom/attachment joystick

backward. To lower the boom, push boom/
attachment joystick forward.
2. Release joystick to stop.
Figure 2-11 Front Steering
ZB20032
TM

Section 2 - Operation Start Operation
2.10-7 Extending or Retracting Boom 2.10-8 Handling Loads
WARNING WARNING
Ensure that there are no personnel or • Before commencing operation, familiarize yourself
obstructions and there is sufficient room with the capacity charts specific to telehandler
to perform all telehandler functions. model and attachment.
1. To extend the boom, move the boom/attachment • Know the weight of the load and the most extreme
joystick to the right. To retract the boom, move the height and distance required to pick or place the
boom/attachment joystick to the left. load.
2. Release joystick to stop. • Do not lift load on a gradient steeper than 5%.
• Never position 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 capacity could cause tipover resulting in death
or serious injury.
• When performing lift operation where the operator

cannot see load at all times, the operator has to
be assisted by a spotter using approved hand
signals. (refer to forklift signals label inside cab).
1. Drive as close as possible to load pickup/

placement site.
2. Place transmission into neutral position. Select

parking brake into on position.
3. Level the frame before lifting the load.
4. Use outriggers for maximum stability.
5. Use attachment to pickup/place the load. Refer

to procedure Section 2.14 for specific attachment
uses.
6. Retract and keep the attachment/load as low as

practical.
ZB20032
TM

2.10-9 Parking and Shutting-down the 2.11 Refueling Procedure

Telehandler (Diesel Fuel Only)
This section provides the operator with procedure on
CAUTION how to refuel telehandler.
Operator should observe the following
IMPORTANT
when parking the telehandler:
Before using your telehandler ensure
there is enough fuel for expected use.
• Avoid parking on slopes or near
excavation, ditches or soft fills. If
• Use extreme caution while refueling
parking on slopes cannot be avoided,
telehandler.
ensure telehandler is positioned at a
right angle across the slope. • Ensure that engine and all systems are
turned off before refueling.
• Avoid parking on roads or highways. If
it cannot be avoided, ensure to display • Refuel the telehandler only in a well
warning flags during the day and flares ventilated area away from open
or flashing lights at night. flame and other sources of ignition,
authorized by your employer and
1. Position telehandler on a firm and level surface.
supervisor.
WARNING • To minimize possible static electricity

Always engage parking brake before fires, ensure filler nozzle touches rim of
leaving the cab. filler opening to aid the dissipation of
static electricity.
2. Engage parking brake.
• Never try to start telehandler if you
smell diesel.
3. Move transmission shift lever to neutral position.
4. Ensure transmission gear selector is in first gear WARNING

position. Do not smoke in an area where
telehandlers are stored or refueled.
5. Retract boom fully and position attachment on the
ground. 1. Ensure engine and all systems are turned off.
6. Allow engine to idle for 3 to 5 minutes after a full 2. Open fuel cap.
load operation. Failure to do so will result in a fault
code on the PowerView display unit. 3. Carefully pour diesel fuel into the tank, ensuring
no spillage occurs.
7. Shut off engine and remove key.
4. Close and secure fuel cap.
WARNING 5. Ensure there are no leaks in fuel system.
Ensure that you maintain three points of
contact to mount/dismount the cab. 6. Wipe up any spilled fuel.
8. Dismount from telehandler. 7. Dispose of rags in an approved container.
9. Chock or block tires to prevent telehandler from

rolling.
ZB20032
TM

Notes
ZB20032
TM

Procedures Section 2 - Operation
CAPACITY CHART MODEL ZB20044

Telehandler LOAD CHART COVERS INTEGRAL FORK-POSITIONER/SIDE-SHIFT CARRIAGE Capacity Chart
Attachment
(M) FT
(13.4) 44
WITH OUTRIGGERS 70oG
Telehandler
60o F B
(12.2) 40
O
O Model
M
50o E RATED CAPACITY (LB)
E AT 48" LOAD CENTRE.
X
SA
(11.0) 36
D T 2 3/4" x 6" FORKS
E MAXIMUM LOAD LIMTED
M
40o N
(9.8) 32 S BY FORK CAPACITY
Boom
PL
C I
O
Extension
E
N
(8.5) 28
O
30o B
N
H NO LIFT ZONE.
Height
LY
E (7.3) 24 NO LOAD BEHIND
FRONT FACE OF TIRE.
I
-U
G (6.1) 20 LOAD RATINGS COMPLY WITH
H
SE
20o ANSI/ITSDF B56.6 - 2005
OUTRIGGERS DOWN
T STABILITY REQUIREMENTS FOR
ROUGH TERRAIN FORKLIFTS.
C
(4.9) 16
H
NO LIFT ZONE
6500 LB (2950 KG)
AR
ALL DIM. ARE U.S.A.
(3.7) 12
CUSTOMARY UNITS.
7000 LB
10o
T
(3175 KG)
10000 LB
11000 LB
8500 LB
(4540 KG)
(4990 KG)
(3860 KG)
DIM. IN (BRACKETS)
Boom
IN
(2.4) 8 ARE S.I. UNITS.
C
Angle
AB
(1.2) 4
0o
FACE OF TIRE
0 0
(-1.2) -4
30 28 24 20 16 12 8 4 0 FT FORWARD
Reach
-11o
(8.5) (7.3) (6.1) (4.9) (3.7) (2.4) (1.2) 0 (M) REACH
Figure 2-13 Sample Capacity Chart
2.12 Use of the Capacity Charts 5. The maximum capacity is determined by the
The capacity charts are located in the operator’s cab. intersection lines between height and reach on
They are used to determine maximum load capacity the capacity chart. If the intersection of the lines
for telehandler equipped with different attachment occurs at a division between capacity zones,
combinations. the smaller of the two capacity values must be
used.
To properly use a particular capacity chart, the operator
must first determine the following: Note
The weight of the load must be equal to or
1. Ensure the capacity chart is for the specific less than the number in the capacity zone.
telehandler model and the attachment.
WARNING
2. Determine the weight of the load to be lifted.
When handling load, ensure that boom
3. Determine the height where the load is to be extension indicators and boom angle
picked or placed. indicator remain within previously
determined/calculated capacity zone.
4. Determine the reach where the load is to be picked
or placed.
Boom Angle
Indicator
B C D E
Boom Extension
Indicators
Figure 2-14 Boom Indicators
ZB20032
TM

Section 2 - Operation Procedures
2.12-1 Examples on Reading the Capacity Chart
The Operator must verify that the capacity chart corresponds with both telehandler and attachment model
number.
The following scenarios show various conditions the operator may encounter.
Boom Boom OK to
Load Weight Reach Height Capacity
Angle Extension Lift
1 8,250 lb (3,742 kg) 16 ft (4.8 m) 33 ft (10 m) 46° G 8,500 lb (3,860 kg) YES
2 9,000 lb (4,082 kg) 18 ft (5.5 m) 22 ft (6.7 m) 34° F 8,500 lb (3,860 kg) NO
3 6,500 lb (2,948 kg) 14 ft (4.3 m) 2 ft (0.6 m) -2° D 10,000 lb (4,540 kg) YES
4 13,750 lb (6,236 kg) 6 ft (1.8 m) 37 ft (11.2 m) 65° F 12,000 lb (5,440 kg) NO
5 7,925 lb (3,594 kg) 16 ft (4.8 m) 12 ft (3.6 m) 18° D 8,500 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
SAMPLE ONLY - USE CHART IN CAB
CAPACITY CHART MODEL ZB20044

LOAD CHART COVERS INTEGRAL FORK-POSITIONER/SIDE-SHIFT CARRIAGE
(M) FT WITH OUTRIGGERS 70oG
(13.4) 44
F B
60o O
(12.2) 40 O
M
E RATED CAPACITY (LB)
50o E AT 24" LOAD CENTRES.
Example 1 (11.0) 36 X
D T
E
N
(9.8) 32 40o
C
S
I Example 4
O
N
(8.5) 28
B
H 30o NO LIFT ZONE.
Example 2 E (7.3) 24 NO LOAD BEHIND
I FRONT FACE OF TIRE.
G
H
(6.1) 20
OUTRIGGERS DOWN
LOAD RATINGS COMPLY WITH Example 5
T 20o ANSI/ITSDF B56.6 - 2005
STABILITY REQUIREMENTS FOR
(4.9) 16
ROUGH TERRAIN FORKLIFTS.
(3.7) 12
20000 LB
10000 LB
12000 LB
15000 LB
10o
Example 6
7000 LB
8500 LB
(3175 KG)
(3860 KG)
(4540 KG)
(5440 KG)
(6800 KG)
Example 3 (2.4) 8
(9070 KG) WHEN FULLY RETRACTED
ALL DIM. ARE U.S.A.

CUSTOMARY UNITS.
(1.2) 4
0o DIM. IN (BRACKETS)
ARE S.I. UNITS.
0 0
FACE OF TIRE
-11oo
-11
(-1.2) -4
28 24 20 16 12 8 4 0 FT FORWARD
(8.5) (7.3) (6.1) (4.9) (3.7) (2.4) (1.2) 0 (M) REACH
Figure 2-15 Capacity Chart Examples
Note
This is a sample capacity chart only! DO NOT use this capacity chart.
Use chart inside cab.
Note
If the intersection occurs on a bold line separating the capacity regions, the smaller of the two capacity
values must be used.
ZB20032
TM

Attachment Installation Procedure Section 2 - Operation
2.13 Attachments Installation 2.13-2 Installing Attachments Using the Quick

Most of ZB telehandler attachments are “Quick Attach” Attach Feature
making the attachment change simple and effortless
with no time lost on the job. 1. Ensure attachment is on a level surface.
2.13-1 Removing Attachments Using the 2. Move the transmission lever to neutral and apply
Quick Attach Feature parking brake.
1. Find an elevated, level surface on which to place 3. With subcarriage tilted forward, lower and extend
the attachment. boom so that the quick attach bar is positioned
under attachment hooks (see Figure 2-16-2).
2. Move transmission lever to neutral and apply
parking brake. 4. Engage the attachment by raising the boom and
tilting subcarriage backward, so that attachment
3. Extend and lower boom enough for attachment is just above the ground (see Figure 2-16-3).
to rest on the elevated, level surface and lock bar
latch located at bottom of subcarriage is fully 5. Install lock bar then latch carriage pin-stop, and
accessible (see Figure 2-16-3). install hitch pin to secure attachment in place.
4. Disconnect auxiliary hydraulic oil hoses 6. Connect auxiliary hydraulic oil hoses
(if equipped). (if equipped).
5. Remove hitch pin located at end of lock bar then lift WARNING
carriage pin-stop upward to unlatch and remove
lock bar. Visually check the attachment is correctly
coupled and secured to the boom before
6. Lower boom, resting the attachment on the ground operating the telehandler.
and tilt subcarriage forward until subcarriage bar
is clear of the hooks (see Figure 2-16-2).
7. Retract boom, disengaging the attachment (see

Figure 2-16-1).
Figure 2-16-2
Figure 2-16-1
Figure 2-16-3
ZB20032
TM

Section 2 - Operation Handling Loads
2.14 Handling Loads

5. Deploy outriggers and
WARNING insert forks under the
load and raise it for 5 to
• Use the capacity charts inside the cab to assess if 10 inches.
the lift is within the capacity of the telehandler.
• ZB20044 model has two capacity charts for each WARNING

attachment based on deployment of outriggers. Do not extend boom if lifting maximum
rated load; instead, drive into load.
• Ensure that the load center for the load is at or
within 24 inches of forks.
• Use a spotter when possible to assist in handling 6. Tilt forks backwards and
the load. (refer to forklift signals label located fully retract the boom
inside operator’s cab).
7. Raise outriggers, then
check telehandler stability before transporting the
Front Face load.
of Forks
Transporting a Load
SG ! GN
.EG NILS INR
AI DN A
MO RRAC EPSU W
YLR RF DN S T
.Y SD IHE ON
.GN EPOR LNO AOL G B MO OD
87 IDI P EB SKR NIL RF
LS S
MO TSUMOF
0-C
ED
RF
DE SGN
RU ILS
CES
WARNING
When transporting a load, always
travel according to jobsite and weather
conditions.
Figure 2-17 Load Center

1. Travel to placement site
2.14-1 Handling Loads at Ground Level with load kept as low to
the ground as possible.
Picking up a Load
2. Apply brakes smoothly to bring telehandler to a
1. Move the transmission lever to neutral and apply complete stop before applying parking brakes.
parking brake.
Placing a Load
2. Check that the telehandler is level using the level
indicator. Adjust frame level if necessary. 1. Move the transmission lever to neutral and apply
parking brake.
3. Ensure the forks are as
far apart as possible for 2. Deploy outriggers and check that the telehandler
the width of the load. This is level using the level indicator. Adjust frame level
increases the stability of if necessary.
the load and the lift.
4. Approach load slowly

with forks straight ahead
and perpendicular to the
load.
ZB20032
TM

Handling Loads Section 2 - Operation
5. Deploy outriggers for

3. Extend boom to the maximum stability of
desired reach and telehandler.
tilt forks forward in a
horizontal position. 6. Extend and lower the
boom to insert the forks
WARNING under load and raise it 5 to 10 inches.
Do not extend boom if placing maximum 7. Tilt forks backwards.

rated load; instead back up from load. Fully retract the boom
and raise outriggers,
then check telehandler
4. Place the load in a stability before
horizontal position transporting the load.
then lower boom until
the load is completely Placing a Load
off the forks. Do not apply downward force with
the forks. 1. Shift transmission lever to neutral and apply
parking brake.
5. Free the forks gradually by lowering and retracting
the boom alternately. 2. Deploy outriggers and check that the telehandler
is level using the level indicator. Adjust frame level
6. When forks are clear of the load, fully retract the if necessary.
boom.
3. Raise and extend
7. Raise outriggers and boom until the load
return to transport is perpendicular over
position. placement point.
2.14-2 Handling Loads at Variable Heights 4. Place the load in a

horizontal position and lower boom until the load
Picking up a Load is completely off the forks. Do not apply downward
force with the forks.
1. Shift transmission lever to neutral and apply
parking brake. 5. Free the forks gradually
by lowering and retracting
2. Check that the telehandler is level using the level the boom alternately.
indicator. Adjust frame level if necessary.
6. When forks are clear
3. Ensure the forks are as far apart as possible for of the load, fully retract
the width of the load. This increases the stability the boom and raise
of the load and the lift. outriggers, then return to transport position.
4. Approach load slowly; raise and extend the boom

until the forks are perpendicular to the load.
ZB20032
TM

Section 2 - Operation Handling Loads
2.14-3 Adjusting Forks 2.14-4 Changing Forks

Adjust the location of both forks using the fork positioner The attachment/fork combination is the most frequently
attachment or combination fork positioner/sideshift used combination. Different loads may require changing
attachment (if equipped, refer to Sections 2.14-1 & forks with different ratings.
2.14-2) or position them manually to suit a pallet pocket
spacing as follows:
1. Raise the boom until fork eye is approximately

shoulder high.
2. Tilt the attachment forward until the fork pivots on

the bar and no longer resting on the attachment’s
bottom rail (Figure 2-18). This prevents binding on
the bar, thus aiding its repositioning.
SGN
!G NIN
.EG ILS D RAW
AIR NE
MO RAC D PSUS T
RF
YLR SDA NIHEB ON OD
E .YL OL M
.GN PORP NO SK GNILSORF
IDIL EB R
S M TSU OF
870
-CE
ORF M S
D
DER GNIL
UCE S
S
Figure 2-19 Changing Forks
1. Lower the boom with fork contacting the ground

until approximately half of the fork float is used
up.
2. Remove inner fork bar collars from fork bar.
3. Draw the bar out of the fork eye and attachment

side plate, being careful that the fork doesn’t fall
over, causing possible injury (Figure 2-19).
Figure 2-18 Forks Pivoting on the Bar 4. Reverse steps 1 through 3 to install the replacement
fork.
3. Grasping the fork near its eye, push the fork along
the bar until it is in the correct position.
CAUTION
Be careful not to pinch fingers between the
fork and any portion of the attachment.
ZB20032
TM

Optional Attachments Section 2 - Operation
2.15 Optional Attachments 2.15-2 Combination Fork Positioner/Sideshift

The SKYJACK ZB series telehandler is designed to Attachment
accept a variety of optional “Quick Attach” attachments The Combination fork positioner/sideshift attachment
aside from regular fork carriage attachment. Ensure to allows the adjustment of distance between the forks
use appropriate attachment capacity chart. as well as the movement of entire carriage assembly
to either left or right. This attachment is useful when
2.15-1 Fork Positioner Attachment handling different size pallets that need special
Fork positioner attachment allows operators to adjustment of both forks and carriage.
accurately and easily adjust the distance between forks
to suit different size pallets.
Figure 2-21 Combination Fork Positioner/Sideshift

Attachment
Figure 2-20 Fork Positioner Attachment
Installation Procedure:
1. Remove fork attachment or other attachment from
boom and connect combination fork positioner/
sideshift attachment (refer to Section 2.13).
boom and connect fork positioner attachment
(refer to Section 2.13).
2. Connect auxiliary hydraulic hoses to diverter valve
on yoke.
2. Connect auxiliary hydraulic hoses.
Operation:
Operation:
1. Shift carriage assembly to the right by moving
1. Depress and hold right thumb button “ ” and
joystick forward. Shift carriage assembly to the
move joystick “ ” forward to shift right fork to left by moving joystick backward.
the right. Depress and hold right thumb
button “ ” and move joystick backward “ ” 2. Adjust the distance between forks by pressing and
to shift right fork to the left. holding thumb buttons and moving joystick either
forward or backward.
2. Depress and hold left thumb button “ ” and
= left fork = in
move joystick forward “ ” to shift left fork to the
left. Depress and hold left thumb button “ ” and
move joystick “ ” backward to shift left fork to
the right. = right fork = out
3. Handle load the same as regular fork attachment

(refer to Section 2.13). 3. Handle load the same as regular fork attachment
(refer to Section 2.14).
ZB20032
TM

Section 2 - Operation Optional Attachments
2.15-3 Bridge Stripper Attachment 2.15-4 Pipe and Pole Grappler

The bridge stripper attachment is used to strip falsework Pipe and pole grappler is intended for handling single
or temporary support structures at bridge-construction and multiple pipes.
sites.
Figure 2-23 Pipe and Pole Grappler
1. Remove fork attachment or other attachment

from boom and install pipe and pole grappler
attachment (refer to Section 2.13).
Figure 2-22 Bridge Stripper Attachment
2. Connect auxiliary hydraulic hoses to
Installation Procedure: attachment.
1. Remove fork attachment or other attachment from Operation:

boom and install bridge stripper attachment (refer
to Section 2.13). 1. Approach load with grappler’s clamps open.
2. Connect auxiliary hydraulic hoses to 2. Insert forks under load and lift it, then tilt grappler
attachment. backward so that load will not fall causing possible
injury.
Operation:
3. Close primary clamps by pressing and holding
1. Raise and extend boom to position stripper under left thumb button “ ” and moving the joystick
load.
forward “ ”. With joystick pushed forward,
press and hold right thumb button “ ” to close
2. Move rear joystick “ ” backward to extend secondary clamps and secure the load in place.
stripper pins. 4. Raise or lower boom to appropriate height and

transport load with caution to placement site.
3. Rest load on stripper then lower and retract boom
to appropriate height. 5. Position load carefully over placement point. Open
secondary clamps by pressing and holding right
4. Travel to placement point with load kept as low to thumb button “ ” while moving joystick
the ground as possible.
backward “ ”. With joystick pulled backward,
press and hold the left thumb button “ ” to open
5. Move rear joystick “ ” forward to retract stripper primary clamps.
pins and tilt attachment forward to unload.
ZB20032
TM

2.15-5 Pipe and Pole Handler 2.15-6 Hydraulic Winch

Pipe and pole handler allows the operator to position, Hydraulic winch is used to raise and lower loads
remove and stack support posts used in the construction vertically such as lowering equipment into a shaft with
of bridges and highways. It can also handle other pipes limited access.
and/or poles, and vertically position them.
Figure 2-24 Pipe and Pole Handler
Installation Procedure: Figure 2-25 Hydraulic Winch Attachment
1. Remove fork attachment or other attachment Installation Procedure:

from boom and install pipe and pole handler
attachment (refer to Section 2.13). 1. Remove fork attachment or other attachment
from boom and install winch attachment (refer to
2. Connect auxiliary hydraulic hoses to Section 2.13).
attachment.
2. Connect auxiliary hydraulic hoses to
Operation: attachment.
1. Approach load with handler’s clamps open.

WARNING
2. Position handler so that load is in the center of Only qualified service personnel should
clamps. install hydraulic winch.
3. Close clamps by moving joystick “ ” forward Operation:

and transport load to placement site.
1. Attach load to winch hook using proper cables or
4. To rotate the pole and pipe handler 90° counter-
clockwise, press and hold “ ” the left thumb chains and move joystick “ ” backward to
button and move joystick “ ” forward. winch up the load.
5. Press and hold “ ” the left thumb button and 2. While helpers guide the load with tag lines,
position load at placement point.
move joystick “ ” backward to rotate pole and
pipe handler 90° clockwise. 3. To winch down the load, move joystick “ ”
forward until load is rested safely on placement
6. Position load carefully over placement point and point. Release cables or chains from winch
open the clamps by moving the joystick “ ” hook.
backward.
ZB20032
TM

Section 2 - Operation Optional Attachments
2.15-7 Jib Boom Attachment (5-ft) 2.15-8 Light-material Bucket

A jib boom is an attachment with a hook or jib eye load A material bucket has a high back and straight sides
connection. This connection is used for extending the for cutting into piles of low density materials. This
forward reach and lift height of the telehandler at the attachment is used for light material handling such as
expense of load capacity. snow removal or transporting of grains and other loose
materials. Material buckets are not meant for excavation
as high twisting loads can damage the boom.
Figure 2-27 Light-material Bucket
Figure 2-26 Jib Boom Attachment (5 ft.) Installation Procedure:
1. Remove fork attachment or other attachment

Installation Procedure: from boom and connect material bucket (refer to
Section 2.13).
boom and connect jib boom attachment (refer to Operation:
Section 2.13).
1. Raise or lower boom to appropriate height for
WARNING loading material from stockpile.
Mounting jib boom changes center of 2. Position telehandler so that it is perpendicular to

gravity of telehandler. Consult capacity the stockpile. Drive slowly and smoothly into pile
charts specific to attachment before to load bucket.
handling loads.
3. Using the optional attachment joystick, tilt bucket
Operation: backwards enough to retain the load. Back away
from pile.
1. Using boom controller, adjust jib boom over the
center of the load. 4. Drive to the unloading point and keep bucket
approximately 4 feet above the ground.
2. Attach load to the pintle hook using sufficient
chains/cables. 5. Tilt bucket forward to dump load.
3. While helpers guide the load, position load at

placement point.
ZB20032
TM

2.15-9 Coil Boom

Coil boom is used to handle steel coil. This attachment
is similar to carpet poles but has a larger diameter and
a shorter boom.
Figure 2-28 Coil Boom Attachment

boom and install coil boom attachment (refer to
Section 2.13).
Operation:
1. Approach load with boom positioned to the middle

of coil material to be lifted.
2. Insert boom and lift load, then tilt carriage

backward so that load will not fall causing possible
injury.
3. Raise boom to appropriate height and transport

load with caution to placement site.
4. Lower and retract boom to place load carefully.
ZB20032
TM

Notes
ZB20032
TM

Loading/Unloading Section 2 - Operation
2.16 Loading and Transporting 4. Using a spotter, carefully drive telehandler onto
Know all national, state/provincial and local rules which the transporting vehicle.
apply to transporting of telehandlers.
5. Once telehandler is loaded, apply parking
Only qualified personnel shall operate machinery brake and rest the attachment flat on the vehicle
during loading and transporting. platform.
Be sure vehicle capacity and loading equipment 6. Move all controls to neutral position.
hoists, chains, straps, etc., are sufficient to withstand
maximum telehandler weight.
7. Turn key switch to “ ” off position and remove
The transport vehicle must be parked on a level key before transporting.
surface and must be secured to prevent rolling while
8. Chock telehandler wheels (if necessary).
telehandler is being loaded or unloaded.
9. Remove all loose items.
IMPORTANT
All turbo-engines air cleaner and exhaust 10. Anchor down telehandler to transport surface
must be sealed during transport. using tie-down points and secure the forks to the
platform using sufficient straps. (See diagram
below).
2.16-1 Loading and Tie-down
WARNING
1. Ensure telehandler is level prior to loading.
Inspect telehandler for loose or unsecured
2. Fully lower and retract boom and raise outriggers items.
(if equipped).
3. Ensure ramps are correctly positioned.
Fig 2-29 Tie-down points
ZB20032
TM

Section 2 - Operation Loading/Unloading
2.16-2 Towing the Telehandler 3. Remove chocks from wheels.
Important 4. Enter cab and fasten seatbelt.

• Use this procedure only to remove
telehandler from mud or other places 5. Ensure transmission gear selector is in ‘neutral’
where it cannot move under its and the transmission lever neutral lock switch is
own power. When possible, repair in the ‘N’ neutral position.
telehandler on site.
6. Start the engine.
• Always chock wheels of the disabled
telehandler to prevent accidental 7. Release park brake.
movement while preparing for towing.
This is especially important if the failure 8. Start towing the telehandler while operating the
occurs on an incline. steering and brakes.
• Before towing, ensure there are no 9. Move telehandler to a compact level surface.
obstructions around or between
10. Apply park brake.
telehandler and towing vehicle.
11. Turn off engine and remove key from ignition
• The spotter must maintain a safe
switch.
distance and must always be visible to
the operator inside telehandler’s cab.
warning
• Ensure the towing vehicle, chains, tow Ensure that you maintain three points of
bar, etc., are suitable for the job. The contact to mount/dismount the cab.
telehandler weight is stamped on the
serial number nameplate. 12. Dismount from telehandler.
1. Lower or raise boom and outriggers (if equipped) 13. Chock or block wheels to prevent telehandler
enough so that front tie-down points are fully from rolling.
accessible.
2. Carefully fasten tow chains to tie-down points on caution
either front or rear of telehandler frame. Bad traction can cause telehandler or
towing vehicle to slide. Grades can
require additional distance to stop
the telehandler. Be careful if traction
conditions are bad or the machine on an
incline.
Fig 2-30 Towing the telehandler

from front tie-down points
ZB20032
TM

Tables Section 2 - Operation
Table 2.1 Standard and Optional Equipment
MODEL ZB20032 ZB20044
STANDARD EQUIPMENT
Pilot-operated joystick boom & frame level controls 3 3
4 wheel power steering 3 3
Electronic dash and full gauge instrumentation 3 3
Hydraulic frame leveling 3 3
Front Wheel Steering 3 3
Round Steering 3 3
Crab Steering 3 3
Automatic self-leveling forks 3 3
Dual batteries 3 3
Rear axle lock system 3 3
Load capacity charts 3 3
Engine air intake grid heater 3 3
Service and park brake activated transmission disconnect 3 3
ROPS/FOPS operator compartment 3 3
4 wheel drive 3 3
External rear view mirrors 3 3
Automatically activated S.A.H.R. parking brake 3 3
Electric horn and reverse warning alarm 3 3
Anti-skid floor and steps 3 3
Quick disconnect carriage 3 3
OPTIONAL EQUIPMENT
Various carriage and fork sizes 3 3
Outriggers 3 Standard
Foam-filled tires 3 3
Turn signals/lights 3 3
Working lights 3 3
Flashing beacon 3 3
Auxiliary hydraulics 3 3
Fork positioner 3 3
Forkshift/Sideshift Carriage 3 3
Jib boom 3 3
Coil boom 3 3
Enclosed operator cab 3 3
Fenders 3 3
Air conditioning 3 3
Pipe and pole clamp 3 3
Pipe and pole grappler 3 3
Mine code specification 3 3

237B
ZB20032
TM

Section 2 - Operation Tables
Table 2.2 Specifications and Features

Engine
Type Cummins QSB4.5C160T3
Max RPM 2500 rpm
Horsepower @ 2300 RPM 168 HP
Horsepower @ 2500 RPM 163 HP
Fuel type Diesel
Transmission
Type DANA T32000
Speeds forward 3
Speeds Reverse 3
Top Speed 20.5 mph (33 km/h)
Gear Ratios
1st Gear 4.64 : 1
2nd Gear 2.23 : 1
3rd Gear 0.82 : 1
Electrical
System voltage 12 volts negative ground
Standard Batteries
Type HP-31E
Quantity 2
Cranking amperes @ 0°F (-17°C) 725 A
Total cranking amps @ 0°F (-17°C) 1450 A
Cranking amperes @ 32°F (0°C) 1100 A
Reserve capacity 180 minutes
Dimensions
Overall length (less forks) 243 in (617 cm)
Overall width 102 in (259 cm)
Overall Height 108 in (274 cm)
Curb weight (standard machine with open cab) 41,500 lbs. (18,370 kg) 45,000 lbs. (20,000 kg)
Maximum capacity 20,000 lbs. (9,071 Kg)
Wheelbase 138 in (350 cm)
Round steer turning Radius (inside) 220 in (559 cm)
Boom
Number of sections 2 3
Maximum lift height 32 ft. 4 in (985 cm) 44 ft. 10 in (1366 cm)
Maximum forward reach 16 ft 6 in (502 cm) 27 ft 5 in (835 cm)
2¾ x 6 x 60 in 2¾ x 6 x 60 in
Standard Forks
(6.9 x 15.2 x 152.4 cm) (6.9 x 15.2 x 152.4 cm)
Carriage rollback 19° 19°
Carriage forward tilt 80° 80°
Operating Times
Boom extend (at max. boom angle) 13 seconds
Boom retract (at max. boom angle) 9.5 seconds
Boom raise* 19 seconds
Boom lower* 20 seconds
Carriage roll forward 12 seconds
Carriage roll back 12 seconds
Frame level right (stop to stop) ** 15 - 20 seconds
Frame level left (stop to stop) ** 15 - 20 seconds
238-A
* Measured with boom fully retracted.

** Under no circumstances should the frame level cycle take less
than 15 seconds to complete in either direction.
ZB20032
TM

Table 2.3 Tire/Wheel Specifications
Standard Tires
Tire Size 17.50 - 25
Pressure 90 psi
Tire Ply Rating 16 PR
Wheel Nuts Torque 450 - 500 ft.lb
239A
WARNING
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
IMPORTANT
For proper function of each axle differential, all four wheels must have same tire size installed at
all times. Failure to comply with this requirement will reduce the life of the differentials and reduce
overall mobility of telehandler.
ZB20032
TM

Table 2.4 Recommended Fluids/Lubrication
Fuel Type Diesel
Fuel Tank Capacity 49 gal (185 L)
Recommended
ne
15W40 CC/SF
gi
Oil Type
En
Coolant Type 60/40 Ethylene glycol/distilled water
Type ATF Dexron III

on
si
is
sm
Capacity 6.3 gal (24 L)

an
Tr
Differential
SAE 80W-90 GL-5
s
le
Ax
Planetary Wheel Ends
Type Anti-wear ISO Gr. 32

il
O
ic
ul
ra
yd
Tank Capacity 55 gal (208 L)

H
Boom Slide Bearings Sunaplex 992 E.P. 2

se
a
re
General Greasing Multi Purpose E.P.

G
240B
ZB20032
TM

General Maintenance
Before attempting any repair work, turn ignition switch to off position. Preventive maintenance is the
easiest and least expensive type of maintenance.
Table 2.5 Maintenance and Inspection Schedule
Quarterly or Annually or Quarterly or Annually or

Frequency Daily Weekly
250 hours 1000 hours
Frequency Daily Weekly
250 hours 1000 hours
Visual and Daily Maintenance Inspections Function Tests

Labels A Operator's Cab Controls
Electrical A Test Horn A
Safety Switches A Test Reverse Alarm A
Mirrors A Test Lights A
Hydraulic A Test Boom and Attachment Functions A
Cylinders A Test Frame Leveling and Level Indicator A
Frame Test Frame Level Lock A
C*†
Wheel/Tire Assembly A Test Accelerator Pedal A
Drive Axle A Test Driving and Service Brake Functions A
Steer Cylinder Assembly A Test Steering A
Steer Linkage A Test Parking Brake A
Batteries A Test Outriggers (if equipped) A
Engine Air Filter A 220B
Engine Coolant A
Muffler and Exhaust A
Engine Compartment A
Engine Oil Level A
Fuel Leaks A
Hydraulic Pump A
Belts A
C*†
Fuel Tank A
Hydraulic Tank A
Hydraulic Oil A
Hydraulic Return Filter A
Boom
Slide Pads A
Chain A
Boom Angle Indicator 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's Cab Controls A
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.7 and Section 2.8 of this manual.
B - Perform Visual and Weekly Maintenance Inspections & Functions Test. Refer to Section 2.7 and Section 2.8 of this manual.
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.
ZB20032
TM

Table 2.6 Operator’s Checklist
OPERATOR'S CHECKLIST
Serial Number:
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.
P - PASS DAILY
F - FAIL FREQUENTLY
R - REPAIRED QUARTERLY
NA - NOT APPLICABLE ANNUALLY
N/A P F R N/A P F R
Visual and Daily Maintenance Inspections Function Tests
Labels Operator's Cab Controls
Electrical Test Horn
Safety Switches Test Reverse Alarm
Mirrors Test Lights
Hydraulic Test Boom and Attachment Functions
Cylinders Test Frame Levelling and Level Indicator
Frame Test Frame Level Lock
Wheel/Tire Assembly Test Accelerator Pedal
Drive Axle Test Driving and Service Brake Functions
Steer Cylinder Assembly Test Steering
Steer Linkage Test Parking Brake
Batteries Test Outriggers (If Equipped)
Engine Air Filter 222A
Engine Coolant
Muffler and Exhaust
Engine Compartment
Note:
Engine Oil Level
Make a copy of this page or visit the Skyjack web site:
Fuel Leaks www.skyjack.com for a printable copy.
Hydraulic Pump
Belts
Fuel Tank
Hydraulic Tank
Hydraulic Oil
Hydraulic Return Filter
Boom
Slide Pads
Chain
Proximity Sensor
Transmission
Lifting Attachment
Grease Fittings
Grease Fittings on Frame
Grease Fittings on Boom Assembly
Operator's Cab
ROPS/FOPS
Seat
Pedals
Manual
Operator's Cab Controls
ZB20032
TM

Labels Section 2 - Operation
Front & Rear
6 5
ZB20044
2 2
4
1
No. Label Pictorial Description
Skyjack Logo
1 Skyjack logo - black
Crushing Hazard
WARNING
PINCH POINT
2 Danger - Crushing hazard

DEC-181
Skyjack Logo
3 Small Skyjack logo - black
Grease Inside
4
GREASE Grease points
INSIDE DEC-101
Model Number*
5
20044 Product Identifier
*Model number will vary, may not be as shown.
Lift and Tie Down Points
6 Only use these points for lifting or tying down.
ZB20032
TM

Section 2 - Operation Labels
2 3 4 10 Tanks Side
5 9
20044
G! S
NIN SLING
WAR ENDCARRIAGE.
SUSP D FROM
NOT BEHIN S . ERLY
DO LOADONLY
FROM S PROP NG.
SLINGFORK BE SLIDI DEC-078
S MUSTFROM
SLING RED
SECU
Turbo
TRANSMISSION
DIPSTICK
WARNING AND
Maintain correct tire pressure. Use proper
FILLER TUBE
safety precautions when filling tires.
DEC-007 A.T.F. DEXRON III
400990
MAINTAIN 90 psi DEC-183
ATTENTION
TORQUE PER 12 1 10 AND THEN PER
SEQUENCE 5 8 SEQUENCE
50-100 3 4 450-500
FT-LBS. FT-LBS.
7 6
DRY 9 11
DRY
2 DEC-303
1 8 7 6 8

Skyjack Logo
Skyjack logo - black
1
Turbo
Telehandler is equipped with a turbo engine.
2
Turbo
Canada & U.S.A. Flags
North American made - North American tough
3
Fuel Strainer and Primer Pump
 Fuel strainer and primer pump location

4 
 
Tire Pressure Warning

WARNING
Maintain correct tire pressure. Use proper safety precautions
5 Maintain correct tire pressure. Use proper
DEC-007
when filling tires.
ZB20032
TM

Tanks Side - Continued

2 3 5 9 4 10
20044
G! S
NIN SLING
WAR ENDCARRIAGE.
SUSP D FROM
NOT BEHIN S . ERLY
DO LOADONLY
FROM S PROP NG.
SLINGFORK BE SLIDI DEC-078
S MUSTFROM
SLING RED
SECU
Turbo
TRANSMISSION
DIPSTICK
WARNING AND
FILLER TUBE
DEC-007 A.T.F. DEXRON III
400990
ATTENTION
50-100 3 4 450-500
FT-LBS. FT-LBS.
7 6
DRY 9 11
DRY
2 DEC-303
1 8 7 6 8

Tire Pressure
Inflate tires to 90 psi maximum
6 MAINTAIN 90 psi DEC-183
Torque sequence and values

ATTENTION
TORQUE PER 10
1
8 AND THEN PER Indicates torque sequence and torque values
7 SEQUENCE
50-100
3 SEQUENCE
6
450-500
FT-LBS. 5 4 FT-LBS.
DRY 7 9 DRY
2 DEC-304
Grease
8 GREASE DEC-005L
Grease point
Model Number*
Product Identifier
9 ZB20044 *Model number will vary, may not be as shown.
ZoomBoom
Zoom Boom logo - yellow and white

10
ZB20032
TM

Cab Side
1 2 3 4 5 6
20044
WARNING
DEC-007
ATTENTION
Turbo
50-100 3 4 450-500
FT-LBS. FT-LBS.
7 6
DRY 9 2 11
DRY
DEC-303
WARN
DO NOT
FROM SUSPEN
ING!
BEHIND D SLINGS
SLING
LOADSCARRIA
SLINGS FORKS FROM GE.
SECUREMUST ONLY.
D FROMBE PROPER
SLIDING LY
.
DEC-078
9 10 9 8 7

-20 Indicates boom elevation angle

1 80
5
11
C-
0 20 40 6 0
DE
ZoomBoom
Zoom Boom logo - yellow and white

2
Tire Pressure Warning

WARNING
Maintain correct tire pressure. Use proper safety precautions
3
DEC-007
when filling tires.
Tire Pressure
Inflate tires to 90 psi maximum

4 MAINTAIN 90 psi DEC-183
Model Number*
Product Identifier
5 ZB20044 *Model number will vary, may not be as shown.
ZB20032
TM

Cab Side
1 2 3 4 5 6
20044
WARNING
DEC-007
ATTENTION
Turbo
50-100 3 4 450-500
FT-LBS. FT-LBS.
7 6
DRY 9 11
DRY
2 DEC-303
WARN
DO NOT
FROM SUSPEN
ING!
BEHIND D SLINGS
SLING
LOADSCARRIA
SLINGS FORKS FROM GE.
SECUREMUST ONLY.
D FROMBE PROPER
SLIDING LY
.
DEC-078
9 10 9 8 7

Turbocharged
6
Turbo Telehandler is equipped with a turbocharged engine.
Canada & U.S.A. Flags

North American made - North American tough
7
Skyjack Logo
Skyjack logo - black

8
Grease
Grease point
9 GREASE
DEC-005R
ATTENTION
Torque sequence and values
1
TORQUE PER 10 8 AND THEN PER
SEQUENCE 3 SEQUENCE
6
Indicates torque sequence and torque values

50-100 450-500
FT-LBS. 5 4 FT-LBS.
10 DRY 7
2
9 DRY
DEC-304
ZB20032
TM

1 2 3
2004
4 4

Oil Type Label
TRANSMISSION
DIPSTICK
1 AND
FILLER TUBE
Transmission dipstick and filler tube ATF Dexron III
A.T.F. DEXRON III
400990
Caution!
CAUTION
2
PRESSURIZED-
COOLING SYSTEM Pressurized cooling system - Remove cap slowly
REMOVE CAP
SLOWLY
DEC-057


Air Vent
 


Coolant fluid filling instructions



3















Coolant Fluid
NOTE
WHEN ADDING OR CHANGING THE COOLANT,
USE 60/40 SOLUTION OF *CUMMINS
Follow these instructions when adding coolant fluid

RECOMMENDED ETHYLENE GLYCOL COOLANT
4
AND WATER.
NEVER DILUTE THE COOLANT, OR THE LIFE OF
THE ENGINE MAY BE SERIOUSLY SHORTENED.
CHECK OR ADD COOLANT AT THE RESERVE
TANK, NOT THE RADIATOR.
* CUMMINS ENGINEERING STANDARD (CES) 14603
ALWAYS USE DISTILLED OR DEIONIZED WATER

Grease
5
GREASE
DEC-005R
Grease point to the right
ZB20032
TM

Tanks
2 1

Diesel Fuel Only
Refill fuel tank with diesel fuel only.
1 DIESEL FUEL ONLY DEC-010
Hydraulic Oil
Refill Hydraulic oil tank with all weather type hydraulic oil.
HYDRAULIC OIL
2
ALL WEATHER TYPE
SEE OPERATORS SERVICE MANUAL
DEC-009
ZB20032
TM

Operator’s Cab
Labels
WARNING
DEC-016
1
2
4
3
ELECTROCUTIO
N HAZARD
5 1
21
EVERY 40 HRS
OF SERVICE UNLESS
PSI
NOTED
1
KEEP CLEAR
CLEAN AND OIL
BRAKE PEDAL
2 PIVOT PIN
GREASE AXLE
10 4 PLS
RESULT FROM 1. STOP
PLS
LOCK CYLINDER
6 TOP & BTM
DEC-002 6 8 GREASE AXLE
7
22
PSI
PLS
4
7 GREASE SLIP JOINT
14 PLS
18 8 GREASE DRIVE
PLS
12 9 GREASE FRAME
BOTH CYLINDERS
11
PINS
15 11 GREASE SLAVE
BOTH CYLINDERS
12 GREASE CARRIAGE
13 BOTH CYLINDERS
13 GREASE CARRIAGE
PIVOT BEARINGS
14 GREASE EXTENSION
9 CHAIN AND ROLLER
3 PLS
LIGHTS
CHAIN ROLLERS
to be signalman
operator can see
you
10 OF SERVICE
3
DEC-024 65-70 PSI
ACCUMULATOR
DEC-302
5





 
The

 

 


Reach

 
 
 



Machine
CK
JOYSTI
ION FORWARD
3 FUNCT HOLD
TILT
AND TILT
PUSH FORK
FORK
BACK
FOR
LOWER
BOOM
BOOM
EXTEND
DEC-142
BOOM
RETRACT RAISE
BOOM
FRAME
LEVEL
EL
T F G I R
DEC-055
TH
6 CHECK DAILY
OPERATING
on Forks
for Road Travel
Brake ONLY
Rated Lifting
:Wheel Studs/
Nuts
- Inspect Lift
Drive
and Welded
to ensure Proper
BRAKES: TRAVELLING:
:Pedal Response
Tilted Back to
Forks Height
Ammeter/Voltmeter
1. Apply Park
Brake
in "NEUTRAL"
on Flat, Level
Freezing
WORK SAFETY:
TIRES:
punctures any time
Control Levers
- Thoroughly
Operator Manual
before Operating
"SPECIALISTS
IN ROUGH TERRAIN
FORKLIFTS"

Danger! Electrocution Hazard keep clear
DANGER
1 ELECTROCUTION HAZARD
KEEP CLEAR Electric shock warning
DEATH OR SERIOUS INJURY CAN RESULT FROM
CONTACT WITH LOAD, MACHINE OR VEHICLE
IF THEY BECOME ELECTRICALLY CHARGED
DEC-002
FORKLIFT SIGNALS Forklift Signals

1. STOP 2. RAISE LOAD 3. LOWER LOAD
2 4. TILT FORKS RIGHT 5. TILT FORKS LEFT 6. TILT FORKS UP Follow these directions when assisted by a spotter.
7. TILT FORKS DOWN 8. MOVE LOAD BACKWARD 9. MOVE LOAD FORWARD
INSTRUCTIONS TO SIGNAL MEN
1. Only one person to be signalman 3. Signalman must watch the load––
2. Make sure the operator can see you the operator is watching you
and is able to acknowledge the 4. Never raise or lower the load over other
signal given workmen, warn them to keep out of the way
WATCH FOR OVERHEAD LINES OR OTHER OBSTRUCTIONS DEC-024
Service Chart
1 CHECK ENGINE OIL LEVEL
ZB12032
2 CHECK AND CLEAN ENGINE AIR FILTERS
3 CHECK ENGINE COOLANT LEVEL AT COOLANT RESERVOIR
7 8 9 10
35 5 CHECK HYDRAULIC FLUID LEVEL
14 EVERY 8 HRS 6 CHECK TRANSMISSION FLUID LEVEL
OF SERVICE 7 CHECK FUEL LEVEL AND OTHER GAUGES ON CAB DASH PANEL
67 8 CHECK CONTROLS IN CAB
66 9 CHECK DEAD ENGINE BRAKING
12 10 CHECK PROPER OPERATION OF BRAKES
37 61 11 CHECK THAT BACK-UP ALARM IS FUNCTIONING PROPERLY
53 37 61
54 11 2
12 GREASE AXLE LOCK PIVOT PINS (2 PLS)
29 6 13 -
3 14 OIL BRAKE AND THROTTLE PINS (IN CAB)
65 15 GREASE AXLE MAIN PIVOT (FRONT AND BACK)
16 GREASE LIFT CYLINDER PIVOTS (2 IN FRAME, 2 IN BOOM)
40
17 GREASE MAIN BOOM PIVOT BEARINGS (2)
32 33 18 GREASE STEERING CYLINDER PINS (4 PLS)
18 19
55 19 GREASE AXLE KING PINS, TOP AND BOTTOM, FRONT AND REAR (8 PLS)
FRONT AND REAR 20 GREASE FRAME LEVEL CYLINDER PINS (TOP AND BOTTOM)
21 GREASE SLAVE CYLINDER PIVOT BEARINGS (4 PLS)
22 GREASE CARRIAGE TILT CYLINDERS (4 PLS)
23 GREASE SUB CARRIAGE PIVOT BEARINGS (2)
EVERY 40 HRS 24 -
OF SERVICE 25 GREASE HIGH LOAD BEARING PADS (FRONT BOTTOM, BACK TOP)
26 -
15 31 27 GREASE DRIVE SHAFT FITTINGS
31 27
27 28 -
CHECK COOLANT FREEZING POINT, CLEAN RADIATOR & COOLER FINS
3
15 29
68 46 30 CHECK FOR STEERING ALIGNMENT, FRONT,BACK AXLES TIMED RIGHT

31 CHECK AXLE PINION SEALS FOR LEAKS (2)
32 CHECK AXLE HUB SEALS & AXLE SHAFT SEALS FOR LEAKS (4)
33 CHECK BRAKE BLEEDER VALVES FOR LEAKS (4)
34 CHECK TIRE CONDITION AND PRESSURE
Identifies the location of grease & service points.

25
35 CHECK BRAKE PEDAL FREE PLAY, 1/8" TO 1/4"
16 36 CHECK OIL LEVEL IN PLANETARY HUBS
37 CHECK AXLE DIFFERENTIAL OIL LEVEL
22 38 -
EVERY 100 HRS 39 CLEAN EXTERIOR SURFACES
OF SERVICE 40 CHECK BATTERY ELECTROLYTE LEVEL
21 41 INSPECT FOR LOOSE FASTENERS, OIL LEAKS, UNUSUAL WEAR OR DAMAGE
42 CHECK ENGINE RIB BELT
22 43 -
48 47 44 CHECK WHEEL NUTS
25
23 45 CHANGE ENGINE OIL AND FILTER (AFTER FIRST 100 HRS OF SERVICE)
50 46 -
17 62
51 49 59
47 CHECK TENSION OF HOSES AND ELECTRICAL CORD INSIDE BOOM
42 EVERY 250 HRS 48 GREASE LOW LOAD BEARING PADS (SIDES, FRONT TOP, BACK BOTTOM)
1 45 57 64 OF SERVICE 49 CHANGE ENGINE OIL AND FILTER
56 50 -
51 CHECK/CLEAN TRANSMISSION BREATHER
58 52 CLEAN HYDRAULIC OIL SUCTION STRAINER
20
21 53 CHANGE AIR FILTER ELEMENTS AND RESET FILTER MINDER
54 CHECK RADIATOR HOSES AND RAD CAP
36 60 55 CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE
EVERY 500 HRS 56 CHANGE TRANSMISSION FILTER
OF SERVICE 57 CHANGE FUEL FILTER, CHECK FOR WATER IN FUEL USING PV-100
58 CHANGE FILTER IN WATER/FUEL SEPARATOR
59 CHANGE TRANSMISSION FLUID & CLEAN SUMP SCREEN
16 52 60 CHANGE PLANETARY GEAR OIL
34 63 61 CHANGE AXLE DIFFERENTIAL OIL
4 5 4
62 CHECK FAN BELT TENSIONER
34 63 CHANGE HYDRAULIC FLUID, CLEAN TANK AND SUCTION STRAINER
44 64 CHANGE HYDRAULIC FLUID RETURN FILTER
EVERY 1000 HRS 65 CLEAN ENGINE COOLANT SYSTEM
OF SERVICE 66 CHECK GAS PRESSURE IN BRAKE ACCUMULATORS, 500 PSI (2 PLS)
THIS CHART FOR OPERATOR REFERENCE ONLY! 67 CHECK GAS PRESSURE IN AXLE LOCK ACCUMULATOR, 175 PSI
68 -
69 CHECK ALL HYDRAULIC SYSTEM PRESSURES
70 CHECK COOLANT TEMP,ENGINE OIL PRESSURE,TRANSMISSION OPERATING TEMP
402261 71 CHECK CHARGING SYSTEM
Lights (if equipped)
4 LIGHTS Identifies the location of light switches

DEC-178
Tilt-console lock
5 Location of tilt-console lock lever
CHECK DAILY
GENERAL:
AXLES:
:Radiator and battery level
:Hydraulic Hoses and Fittings
:Transmission Fluid, Hydraulic Oil
:Mounting Bolts
OPERATING INSTRUCTIONS:
- Centre Load on Forks
- Beware of Overhead Obstacles
- Observe All Operating and Safety Decals on Machine
- Bring Unit to a Full Stop Before Changing Direction
- Use High Gear for Road Travel of Unloaded Unit ONLY
- Disengage Park Brake
- Never Exceed Rated Lifting Capacity -- See Factory Load Chart
- Feather Hydraulic Controls when Nearing Maximum Mast/Boom Extension
- Inspect Lift Component( Mast or Boom ) Chains, Rollers, Pins and Welded
Components
Daily Check Label
:Wheel Studs/ Nuts - Cycle Each Hydraulic Function at Start of Day to ensure Proper
:Oil Leaks at Drive Hubs and Differential Operation
:Two Wheel Drive Units Only--Steer
TRAVELLING:
- Keep Telescopic Booms Fully Retracted
BRAKES:
6
:Pedal Response - Keep Carriage Tilted Back to Avoid Spills
:Clean Mud and Debris from Brake Pedal Assembly - Travel with Load at Lowest Practical Height
- Always Have Forks Pointed Up Hill on a Grade
- Travel in Reverse if Load Obstructs Forward Vision
ELECTRICAL: :All Exposed Wiring PARKING PROCEDURE:
Check daily before operating the telehandler.

:Proper Operation of All Gauges
:Charging System Ammeter/Voltmeter 1. Apply Park Brake
2. Place Transmission in "NEUTRAL"
3. Park Machine on Flat, Level Surface or Chock Wheels
4. Park Machine with Forks, Slightly Clear of Ground to Avoid Freezing
ENGINE: :Hoses in Mud during Winter Operation
:Belts
:Fluid Levels/ Leaks WORK SAFETY:
- No Riders at any time
- Only Trained, Authorized Operators
TIRES: :Gouges, cuts, punctures - Operate Machine Only From Operator Seat
:13:00 and 14:00 X24 Grader Lug -- 65 PSI Unloaded - Use Only Approved Personnel Platforms
:Rims -- Examine for Cracks, Distortion, Lock - Do Not Use Control Levers or Steering Wheel as Grab Handles
Ring Assembly - Never Make any Unauthorized Alterations or Adjustments
- Never Tilt Carriage when Personnel Platform is Used
- Thoroughly Read and Understand Operator Manual before Operating
"SPECIALISTS IN ROUGH TERRAIN FORKLIFTS"
ZB20032
TM

Operator’s Cab
Labels - Continued
1
WARNING
DEC-016
3
4
ELECTROCUTIO
N HAZARD
5 1
21
EVERY 40 HRS
OF SERVICE UNLESS
PSI
NOTED
1
KEEP CLEAR
CLEAN AND OIL
BRAKE PEDAL
2 PIVOT PIN
GREASE AXLE
10 4 PLS
RESULT FROM 1. STOP
PLS
LOCK CYLINDER
6 TOP & BTM
DEC-002 6 8 GREASE AXLE
7
22
PSI
PLS
4
7 GREASE SLIP JOINT
14 PLS
18 8 GREASE DRIVE
PLS
12 9 GREASE FRAME
BOTH CYLINDERS
11
PINS
15 11 GREASE SLAVE
BOTH CYLINDERS
12 GREASE CARRIAGE
13 BOTH CYLINDERS
13 GREASE CARRIAGE
PIVOT BEARINGS
14 GREASE EXTENSION
9 CHAIN AND ROLLER
3 PLS
LIGHTS
CHAIN ROLLERS
to be signalman
operator can see
you
10 OF SERVICE
3
DEC-024 65-70 PSI
ACCUMULATOR
5
DEC-302





 
The

 

 


Reach

 
 
 



Machine
CK
JOYSTI
ION FORWARD
3 FUNCT HOLD
TILT
AND TILT
PUSH FORK
FORK
BACK
FOR
LOWER
BOOM
BOOM
EXTEND
DEC-142
BOOM
RETRACT RAISE
BOOM
2
FRAME
LEVEL
EL
T F G I R
DEC-055
TH
CHECK DAILY
OPERATING
on Forks
for Road Travel
Brake ONLY
Rated Lifting
:Wheel Studs/
Nuts
- Inspect Lift
Drive
and Welded
to ensure Proper
BRAKES: TRAVELLING:
:Pedal Response
Tilted Back to
Forks Height
Ammeter/Voltmeter
1. Apply Park
Brake
in "NEUTRAL"
on Flat, Level
Freezing
WORK SAFETY:
TIRES:
punctures any time
Control Levers
- Thoroughly
Operator Manual
before Operating
"SPECIALISTS
IN ROUGH TERRAIN
FORKLIFTS"
WARNING
Fork Danger
1 Fork danger decal

DEC-016
The Reach Machine

The
2 Reach The reach machine logo
Machine
3 FUNCTION JOYSTICK
PUSH AND HOLD FORWARD
3 Function Joystick (Boom)
FOR FORK TILT
FORK TILT
3 BOOM LOWER
BACK
Boom and fork tilt functions joystick

BOOM BOOM
RETRACT EXTEND
BOOM RAISE DEC-142



3 Function Joystick (Attachment)*
 

4 







Auxiliary attachment functions joystick

*Label will vary, may not be as shown.
 
  
 


Frame Level
FRAME
LEVEL
5 L
E
R
I
G Frame level left or right
F H
T DEC-055 T
Serial Plate*
6 Product identification and specifications

*Serial plate will vary, may not be as shown.
ZB20032
TM

Dash Panel
Labels
4 5 6 7 8
IMPORTANT
WARNING WARNING
WARNING WARNING
BACKUP ALARM
ALARM MUST SOUND WHEN BACKING 2. ALWAYS LOWER AND RETRACT ENERGIZED WHEN RED LIGHT IS LIT.
No Riders BOOM BEFORE MOVING MACHINE. NEVER ATTEMPT TO LEVEL FRAME
1
TO OPERATE THIS VEHICLE SAFELY 3. NEVER USE FRAME LEVELLING WHEN BOOM IS ELEVATED OR
BE SURE BACKUP ALARM IS OPERATING WHEN BOOM IS ELEVATED. WHEN RED LIGHT IS LIT.
DEC-109 DEC-099 DEC-100
DEC-013A
Extending ourselves
for you.




2



DANGER
20044

 
 
DO NOT OPERATE  
 
THIS MACHINE  
WITHOUT SEAT  
 
BELT FASTENED  
DEC-023
IMPORTANT

MPORTANT
9


BUCKETS ON FORKLIFT 
ARE FOR LIGHT MATERIAL 
HANDLING ONLY 

THEY ARE NOT INTENDED 
FOR EXCAVATINGDEC-224
IMPORTANT
ALL TURBO-ENGINES
AIR CLEANER AND EXHAUST BRAKE LOCK LOCK PRESSURE
DEC-320
TRANSPORT DEC-052
DEC-322
BRAKE ACTUATED
TRANSMISSION HORN
DISCONNECT BRAKE BRAKE LEFT RIGHT DEC-308E
LEFT RIGHT
NORMAL
TRANSMISSION FRONT
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
DEC-216
3
12 11 10

Danger! Seat Belt Warning
DANGER
1 DO NOT OPERATE
THIS MACHINE Do not operate telehandler without seat belt fastened.
WITHOUT SEAT
BELT FASTENED
DEC-023
Bucket Attachment*
IMPORTANT
BUCKETS ON FORKLIFT
2 ARE FOR LIGHT MATERIAL
HANDLING ONLY
Indicates bucket attachments on forklif are for light material
handling only.
THEY ARE NOT INTENDED
*If Equipped.
Function Switches
BRAKE ACTUATED
STEERING PARKING SECONDARY OUTRIGGERS HIGH
TRANSMISSION
DISCONNECT BRAKE BRAKE LEFT RIGHT IDLE
NORMAL
OPERATION ROUND ON ON DOWN DOWN HIGH
3 TRANSMISSION
DISCONNECT
OVERRIDE
FRONT Use these switches to select steering mode, set parking brake,
secondary brake and deploy outriggers if equipped.
TO BE USED FOR
RAMPING OPERATIONS
ONLY CRAB OFF OFF UP UP NORMAL
413897
IMPORTANT
CUMMINS QSB ELECTRONIC ENGINE.
Battery Disconnection/Connection Procedure
TO PREVENT COMPUTER DAMAGE,
FOLLOW PROCEDURE BELOW:
4 VEHICLE BATTERY DISCONNECTION

1. Ensure the Keyswitch has been OFF for
Follow these instructions to connect/disconnect battery.

at least 1 Minute.
2. Disconnect the POSITIVE Battery Cable.
3. Disconnect the NEGATIVE Battery Cable.
VEHICLE BATTERY CONNECTION
1. Connect the NEGATIVE Battery Cable.
2. Connect the POSITIVE Battery Cable.
DEC-318
No Riders Warning
WARNING
6
No Riders Absolutely no riders on telehandler.
DEC-013A
WARNING
Back-up Alarm Warning
5
BACKUP ALARM
Telehandler is equipped with a back-up alarm.

BE SURE BACKUP ALARM IS OPERATING
DEC-109
ZB20032
TM

Dash Panel
Labels - Continued
4 5 6 7 8
IMPORTANT
WARNING WARNING
WARNING WARNING
BACKUP ALARM
1
DEC-109 DEC-099 DEC-100
DEC-013A
Extending ourselves
for you.




2



DANGER
20044

 
 
DO NOT OPERATE  
 
THIS MACHINE  
WITHOUT SEAT  
 
BELT FASTENED  
DEC-023
IMPORTANT

MPORTANT
9


HANDLING ONLY 

IMPORTANT
ALL TURBO-ENGINES
DEC-320
TRANSPORT DEC-052
DEC-322
BRAKE ACTUATED
TRANSMISSION HORN
LEFT RIGHT
NORMAL
TRANSMISSION FRONT
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
DEC-216
3
12 11 10

Telehandler Leveling Warning
WARNING
7 BEFORE RAISING BOOM.

BOOM BEFORE MOVING MACHINE. Always level telehandler prior to starting any function.
3. NEVER USE FRAME LEVELLING
WHEN BOOM IS ELEVATED.
DEC-099
Do not level when boom is raised.
Rear Axle Tilt Lock Warning

WARNING
8 AXLE TILT LOCK WHICH IS

NEVER ATTEMPT TO LEVEL FRAME Telehandler is equipped with rear axle tilt lock.
WHEN BOOM IS ELEVATED OR
WHEN RED LIGHT IS LIT.
DEC-100
Electronic Panel Display Labels

PARK AXLE CHARGE
9 BRAKE LOCK PRESSURE Indicates park brake, axle lock, and charge pressure status
DEC-321
lights.
Starting Procedure
10 TO INITIALIZE, THEN START ENGINE. Turn key to ON, wait for gauge to initialize, then start engine.
DEC-322
Horn
11 HORN DEC-308E
Horn label
Transportation Reminder
IMPORTANT
12 ALL TURBO-ENGINES
Ensure engine, air cleaner, and exhaust are sealed during
transportation.
TRANSPORT DEC-052
ZB20032
TM

Dash Panel
Labels - Continued
13
IMPORTANT
WARNING WARNING
WARNING WARNING
BACKUP ALARM
14
DEC-109 DEC-099 DEC-100
DEC-013A
Extending ourselves
for you.




15



DANGER
20044

 
 
DO NOT OPERATE  
 
THIS MACHINE  
WITHOUT SEAT  
 
BELT FASTENED  
DEC-023
IMPORTANT



MPORTANT
HANDLING ONLY 

IMPORTANT
ALL TURBO-ENGINES
DEC-320
TRANSPORT DEC-052
DEC-322
BRAKE ACTUATED
TRANSMISSION HORN
LEFT RIGHT
NORMAL
TRANSMISSION FRONT
DISCONNECT
OVERRIDE
TO BE USED FOR
RAMPING OPERATIONS
DEC-216
16

Reserve Steering Accumulator



Indicates when steering is using accumulator reserve pressure.
13 



Park Brake and Secondary Brake


 



 Indicates operating instructions for park brake and secondary
14 


 brake if equipped.
 
 
 
Standards Compliance*

Indicates telehandler complies with SAE Standards


15 




*If equipped, label may vary.
Important Safety Reminder
IMPORTANT Tighten wheel nuts daily and check axle spring mounting bolts
1. TIGHTEN WHEEL NUTS DAILY
16 FIRST 150 HOURS OPERATION regularly.
2. CHECK AXLE & SPRING
DEC-022
ZB20032
TM

Notes
ZB20032
TM

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.
WASH HANDS AFTER HANDLING.

Reliable lift solutions by people who care.
www.skyjack.com

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MODELS ZB20032 ZB20044

Part No. 402505AC-A August 2010

ZB20044 December 2007 Page 3

Read and Heed

Page 4 December 2007 ZB20044

2.9 Function Tests..................................................................................................................................................35

2.1 Standard and Optional Features......................................................................................................................64

ZB20044 December 2007 Page 5

Page 6 December 2007 ZB20044

Service Policy and Warranty

Scope of this Manual

- Equipment identified with “ANSI” meets the ANSI/ITSDF B56.6 standard.

c. ANSI (United States)

ZB20044 December 2007 Page 7

Operator Safety Reminders

Page 8 December 2007 ZB20044

DO NOT USE TELEHANDLER AS A GROUND FOR WELDING.

ZB20044 December 2007 Page 9

• MAKE SURE all DANGER, WARNING, CAUTION

• KNOW all national, state/provincial and local rules

• DO NOT wear loose

Page 10 December 2007 ZB20044

Safety Precautions (Continued)

• DO NOT elevate the boom

ZB20044 December 2007 Page 11

Safety Precautions (Continued)

• TRAVEL SLOWLY over

• WALK AROUND the

Page 12 December 2007 ZB20044

Safety Precautions (Continued)

• DRIVE DOWNHILL • SECURE loose loads

ZB20044 December 2007 Page 13

Safety Precautions (Continued)

Page 14 December 2007 ZB20044

Safety Precautions (Continued)

• Do use three points of contact to enter and exit

• Three points of contact means that two hands

• does not appear to be working properly.

Failure to avoid these hazards could

ZB20044 December 2007 Page 15

Page 16 December 2007 ZB20044

2.0 Operation 2.1-2 Operator’s Responsibility for

2.1-4 Owner’s Inspections

ZB20044 December 2007 Page 17

2.2 Major Components

Engine Air Intake

Frame Level Cylinders

Outriggers Rear Axle Rear Axle

Page 18 December 2007 ZB20044

2.3 Major Assemblies 2.4 Serial Number Nameplate

2.3-1 Frame • Model number

2.3-3 Boom Assembly

Boom assembly also includes a subcarriage which

ZB20044 December 2007 Page 19

2.5 Component Identification

2.5-1 Boom Angle Indicator

Figure 2-2 Telehandler Seat

A fully-enclosed cab with windows and door is Manual Storage Box