Skyjack ZB12032 User manual

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

Skyjack Service Center 3451 Swenson Ave. St. Charles, Illinois, 60174 USA
Phone: [phone]
Toll Free: 1-800-275-9522
Fax: [phone]
Email: [email protected]om
Parts (North America)
Toll Free: 1-800-965-4626
Toll Free Fax: [phone]
Email: [email protected]
Parts & Service (Europe) Unit 1 Maes Y Clawdd, Maesbury Road Industrial Estate
Oswestry, Shropshire SY10 8NN UK
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Skyjack Asia Pacific
Singapore
Phone: [phone]
Fax: [phone]
Email: [email protected]

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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.
The Safety Alert Symbol identifies important
safety messages on telehandlers, safety signs
in manuals or elsewhere. When you see this
symbol, be alert to the possibility of personal
injury or death. Follow the instructions in the
safety message.
This Safety Alert Symbol means attention!
Become alert! Your safety is involved.

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ZB12032
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 Operator’s Cab, Seat, Manual Storage Box ...................................................................................20
2.5-2 Operator’s Cab Controls .................................................................................................................21
2.6 Operator’s Responsibility................................................................................................................................26
2.7 Visual and Daily Maintenance Inspections ....................................................................................................27
2.7-1 Labels...............................................................................................................................................27
2.7-2 Electrical ..........................................................................................................................................27
2.7-3 Safety Switches ...............................................................................................................................27
2.7-4 Mirrors..............................................................................................................................................27
2.7-5 Hydraulic..........................................................................................................................................28
2.7-6 Cylinders..........................................................................................................................................28
2.7-7 Frame...............................................................................................................................................28
2.7-8 Engine Compartment ......................................................................................................................30
2.7-9 Boom ...............................................................................................................................................31
2.7-10 Transmission....................................................................................................................................32
2.7-11 Lifting Attachment............................................................................................................................32
2.7-12 Grease Points ..................................................................................................................................32
2.7-13 Operator’s Cab ................................................................................................................................34
Table of Contents
Section 1 - About Your Telehandler

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2.8 Function Tests..................................................................................................................................................35
2.8-1 Operator’s Cab Controls .................................................................................................................35
2.9 Start Operation ................................................................................................................................................44
2.9-1 Starting the Engine ..........................................................................................................................44
2.9-2 Driving the Telehandler....................................................................................................................45
2.9-3 Driving on Slopes ............................................................................................................................45
2.9-4 Steering the Telehandler..................................................................................................................46
2.9-5 Leveling the Telehandler..................................................................................................................46
2.9-6 Raising or Lowering Boom ..............................................................................................................46
2.9-7 Extending or Retracting Primary the Boom ....................................................................................47
2.9-8 Handling Loads ...............................................................................................................................47
2.9-9 Parking and Shutting-Down the Telehandler...................................................................................48
2.10 Refueling Procedure (Diesel Fuel Only)..........................................................................................................49
2.11 Use of the Capacity Chart ...............................................................................................................................50
2.11-1 Examples on Reading the Capacity Chart ......................................................................................51
2.12 Pipe Grappler Attachment Operation..............................................................................................................52
2.12-1 Handling Loads Using Pipe Grappler .............................................................................................52
2.13 Loading and Transporting ...............................................................................................................................54
2.13-1 Loading and Tie-down.....................................................................................................................54
2.13-2 Towing the Telehandler....................................................................................................................55
2.14 Tables...............................................................................................................................................................56
2.15 Labels ..............................................................................................................................................................62
List of Tables
2.1 Standard and Optional Equipment .................................................................................................................56
2.2 Specifications and Dimensions.......................................................................................................................57
2.3 Tire/Wheel Specifications................................................................................................................................58
2.4 Recommended Fluids/Lubrication..................................................................................................................59
2.5 Maintenance and Inspection Schedule .........................................................................................................60
2.6 Operator’s Checklist........................................................................................................................................61
Table of Contents
Section 2 - Operation (Continued)

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Notes

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Read and Heed Section 1 - About Your Telehandler
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.
Purpose of Equipment
SKYJACK Zoom Boom 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 Zoom Boom telehandler is designed to accept a variety of optional accessories. 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 ZB12032 telehandler.
- Equipment identified with “ANSI” meets the ANSI/ITSDF B56.6-2005 and ASME B56.6 standards.
- 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 are required to conform to national, territorial/provincial
and local health and safety regulations applicable to the operation of this telehandler.
1

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Section 1 - About Your Telehandler Safety Rules
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.

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Safety Rules Section 1 - About Your Telehandler
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.

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Section 1 - About Your Telehandler Safety Rules
Safety Precautions
Know and understand all safety precautions before going on to the next section.
WARNING
Failure to heed the following safety
precautions could result in tip over,
falling, crushing, or other hazards leading
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
which apply to your telehandler and jobsite.
• SHUT DOWN by positioning the telehandler in
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 full load operation. Stop engine and remove
ignition key to prevent unauthorized use. Block
wheels.
• WEAR all the protective clothing and personal
safety devices issued to you or called for by job
conditions.
• DO NOT wear loose
clothing, dangling
neckties, scarves, rings,
wristwatches or other
jewelry while operating
this telehandler.
• DO NOT stand on
forks. Use of forks to
lift personnel is strictly
prohibited.
• DO NOT climb on this
vehicle for any reason.
• BE AWARE of crushing
hazards. Keep head,
arms, hands, legs and all
other body parts inside
the operator’s cab at all
times.
• KEEP OUT from under
boom or near forks while
operating.
• KEEP AWAY from
attachment tilt cylinder
and other pinch points.
• KEEP CLEAR of boom
holes.
• ENSURE that power
is disconnected before
touching any wires.
Electrocution can cause
death or serious injury.
• ENSURE that there are no
personnel or obstructions
in the path of travel,
including blind spots.
• BE AWARE of blind
spots when operating the
telehandler.

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Safety Rules Section 1 - About Your Telehandler
Safety Precautions (Continued)
Know and understand all safety precautions before going on to the next section.
• ALWAYS wear your seat
belt when operating this
vehicle.
• DO NOT exceed the maximum safe operating
slope.
• DO NOT lower the boom
unless the area below is
clear of personnel and
obstructions.
• DO NOT elevate the
boom in windy or gusty
conditions.
• DO NOT drive with boom
elevated.
• DO NOT elevate the boom
while the telehandler is on
a truck, forklift or other
device or vehicle.
• If operation in
areas with holes or
drop-offs is absolutely
necessary,ensure that
all 4 wheels or outriggers
(if equipped) have contact
with firm surface. Then
level the frame. Once
frame is level, the boom
can be elevated. After elevation, the drive function
must not be activated.
• DO NOT use fork
attachment as a crane.
• DO NOT use the frame-
leveling mechanism to
compensate for swinging
loads.
• DO NOT drive with
elevated load.
• DO NOT maneuver a load
while moving. This greatly
increases the chance of
spills and injury.
• DO NOT operate on
surfaces not capable of
holding the weight of the
telehandler; including the
rated load (e.g., covers,
drains, and trenches).

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Section 1 - About Your Telehandler Safety Rules
Safety Precautions (Continued)
Know and understand all safety precautions before going on to the next section.
• AVOID jerks and sudden
stops.
• AVOID entanglement
with ropes, cords or
hoses.
• TRAVEL SLOWLY over
rough terrain.
• KNOW the weight of the
load you are transporting.
Never lift more than the
lifting capacity at any given
extension or elevation of
the boom as listed on the
load charts.
• WHEN
TRANSPORTING
LOADS fully retract the
boom, keep the load low
to the ground and forks
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
stability and decrease
potential for injury to
others. When fully
stopped, lower forks
completely to the ground.
• DRIVE DOWNHILL
UNLOADED. Without
a load, the back end
is the heaviest part of
the telehandler. Driving
downhill decreases
potential for tipover.
• DRIVE UPHILL
LOADED. When holding
a load, driving uphill
decreases potential for
load to slip out.
• TILT forks backwards
slightly when traveling to
decrease potential of load
slipping off.
• SECURE loose loads
with chains or straps to
decrease potential of
spills or injury to others.
• TETHER LOADS that
may swing, keeping
them close to the ground.
Provide ample clearance
for personnel to guide the
load safely.
• DO NOT use frame
leveling when boom is
elevated.

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December 2007 Page 13
Safety Rules Section 1 - About Your Telehandler
Safety Precautions (Continued)
Know and understand all safety precautions before going on to the next section.
• LEVEL FRAME ON
SLOPES before elevating
boom
• IN THE EVENT OF A
TIPOVER brace yourself
against the sides of the
cab and lean away from
the direction you are
falling. The cab is the
safest place to be during
a fall, never attempt to
jump out of it.
• USE CAUTION when
boom is fully extended.
The further out the boom
is extended, the less load
telehandler can support.
• USE CAUTION when
placing loads at high
elevations and on downhill
slopes.
• BE AWARE of all
obstructions while
traveling.
• BE AWARE of the
telehandler’s travel
envelope, especially when
turning. Keep sufficient
clearance at all times
between the telehandler
and any obstacles or
people.
• CHECK for clearance
before traveling between
obstacles.
• KEEP OTHERS AWAY
at all times during
operation.
• CHECK for cracks and
signs of stress.
• WALK AROUND the
telehandler before
operation and check
for any visible signs of
damage or malfunction.
• CHECK lights for proper
function before operating.
2
1

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Page 14 December 2007
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Section 1 - About Your Telehandler Safety Rules
• ENSURE ALL tires are
in good condition and
lug nuts are properly
tightened.
• ALWAYS maintain three
points of contact when
entering vehicle. Use
provided hand-holds and
steps only.
• DO NOT ascend or descend a grade when
elevated. When fully lowered, ascending or
descending, only grades up to rated maximum
listed in Table 2.2 are permissible.
• DO NOT alter or disable safety devices.
• DO NOT try to start the telehandler by pushing
or towing. Such operation may cause severe
damage to the transmission - Refer to Section 2.
• DO NOT burn or drill holes in forks. Modifying
any part of telehandler or attachment affects its
capacity and/or stability.
• IF DRIVING ON ROADS OPEN TO PUBLIC
TRAFFIC respect the local regulations.
• THE OPERATOR’S CAB provides a falling
object protection structure (FOPS) and a rollover
protection structure (ROPS). Do not make any
modification to this structure. If damaged, the
cab cannot be repaired. It must be replaced.
• STUNT driving and horseplay are prohibited.
• ALWAYS USE FRONT steering when traveling
on highways and public roads.
• ALWAYS USE FRONT steering when traveling
at high speeds.
• DO NOT change steering mode while the
telehandler is traveling. Change the steering
mode only when telehandler is stopped.
• ALWAYS look in the direction of travel. Reduce
speed and be especially careful when traveling
in reverse and/or turning. Bring the telehandler
to a complete stop before changing the direction
of travel.
• STAY CLEAR of pinch points and rotating
parts on the material handler. Getting caught
in a pinch point or a moving part can cause
serious injury or death. Before performing any
maintenance on telehandler, follow the shutdown
procedure on Section 2.9-9.
•DO NOT position the telehandler against
another object to steady the load.
Safety Precautions (Continued)
Know and understand all safety precautions before going on to the next section.

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Safety Rules Section 1 - About Your Telehandler
Safety Precautions (Continued)
Know and understand all safety precautions before going on to the next section.
WARNING
Entering and exiting the telehandler
should only be done using the three
points of contact.
• Use only equipped access openings.
• Enter and exit the telehandler only
when the boom is in the fully retracted
position.
•Do use three points of contact to enter and exit
the cab. Enter and exit the platform from the
ground only. Face the telehandler when entering
or exiting 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.
Jobsite Inspection
Do not use in hazardous locations.
•
Perform a thorough jobsite inspection prior to•
operating the telehandler, to identify potential
hazards in your work area.
Be aware of moving equipment in the area. Take•
appropriate actions to avoid collision.

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Notes

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

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

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December 2007 Page 19
Section 2 - Operation
2.3 Major Assemblies
The telehandler consists of four major assemblies: the
frame, boom assembly, attachment and cab.
2.3-1 Frame
The frame is a one-piece weldment that supports the
boom assembly.
2.3-2 Cab
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 consists of two
telescoping boom sections.
2.3-4 Attachment
The attachment is a material-handling device attached
to the boom. The standard attachment is a fork carriage.
Refer to Section 2.12 for various attachments.
2.4 Serial Number Nameplate
The serial number nameplate, located inside the
operator’s cab, lists the following:
Model number•
Serial number•
Maximum capacity•
Maximum lift height•
Machine weight•
Year of manufacture•
Voltage•
Lift capacity•
Original supplied attachments•

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Page 20 December 2007
ZB12032
Section 2 - Operation Component Identification
2.5 Component Identification
The following descriptions are for identification,
explanation and locating purposes only.
2.5-1 Operator’s Cab
The operator’s cab allows vision from all sides and is
equipped with a rollover and falling object protective
structure.
WARNING
The operator’s cab provides a falling
object protection structure (FOPS) and
a rollover protection structure (ROPS).
Do not make any modification to this
structure. If damaged, the cab cannot be
repaired. It must be replaced.
A fully-enclosed cab with windows and door is
available as an option. Included in this option is the
windshield wiper, interior light and air heater/defroster.
Air conditioner tis also available as an option for fully
enclosed cab.
The operator’s seat is equipped with a seat belt. Use this
seat belt at all times when operating telehandler.
Figure 2-1 Telehandler Seat
Seat Belt
Height Adjustment
Ride Control
Adjustment
Fore/Aft
Lock Lever
Seat
The telehandler seat is equipped with devices which
allow for the adjustment of seat height and distance
from the controls. Adjust the seat so that foot pedals,
steering wheel and instrument panel controls are within
easy reach of the operator.
The height adjustment is located on the front of the seat
and is operated by turning the rotary knob. Clockwise
rotation lowers the seat, counter clockwise raises the
seat.
The ride control is located on the left of the seat and
is also operated by means of a rotary knob. Clockwise
rotation decreases the firmness while counterclockwise
rotation increases the firmness.
The fore and aft lock lever is located on the front- left
corner of the seat. Pushing the lever to the left unlocks
the seat, allowing fore and aft adjustment.
WARNING
The seat belt must be worn at all times.
Manual Storage Box
This weather-resistant box is mounted at the back
of the operator’s seat. It contains
operating manual and other important
documentation. The operating
manual for this make and model
of telehandler must remain with the
telehandler and should be stored in
this box.