Operator'S Manual: Hazel Crest, Illinois 60429 - 708/596-5200 - FAX: 708/596-9076

OPERATOR'S
MANUAL
39700458
TRAVELIFT ® CRANE MJ50
SAFETY DECLARATION TO THE OPERATOR
Proper lighting, safety signs, warning bells, etc., can only ASSIST in
preventing an accident. But YOU, the operator, can PREVENT an
accident. YOU, the operator, must act as airline captain, and be
responsible for the personal safety of yourself and all persons around
the machine. When used, the GROUNDCREW should act as your
controller. They can GUIDE you to avoid accidents, such as advising
when the aisles are clear. However, YOU, the operator, have total
responsibility for the safe operation of this machine. You are not to
move it until YOU know it is safe to do so, or have been appropriately
signaled by an appointed ground person.
In some instances groundcrew may be used. However, all operating

environments and situations do not necessitate the use of groundcrew
for safe operation. Therefore, it is the responsibility of the user, based
on the unique requirements of his workplace, to establish appropriate
operating procedures, such as the use of groundcrew, to ensure a safe
working environment.
Any references in this manual to the use of groundcrew is not intended

to dictate their use but only to alert the operator to situations affecting
groundcrew when used.
Wheel guards and optional drive shut-down systems are intended to

protect the tire and wheel assembly only and are not to be misconstrued
as personnel safety devices. F-201b
Hazel Crest, Illinois 60429 • 708/596-5200 • FAX: 708/596-9076
© Copyright • 2006 • MI-JACK Products FEBRUARY 2006

(SMT-0082a
Employees should be aware of possible dangers in operating or working

around intermodal lift equipment. This type of machine operates in and
around intense vehicular and personnel traffic. The busy environment
increases the potential hazard in operating these machines. This naturally
requires alertness and caution by you to prevent accidents while achieving
expected productivity from your machine.
WARNING
Working in the area of industrial equipment is dangerous. Certain

inherent risks are associated with industrial machines due to the
nature of their use. Personnel in the area of industrial machines
are subject to certain hazards that cannot be met by mechanical
means but only by the exercise of intelligence, care, and common
sense. It is therefore essential to have personnel involved in the
use and operation of equipment who are competent, careful,
physically and mentally qualified, and trained in the safe opera-
tion of the equipment and the handling of loads. Failure to do so
could result in personal injury or death. G-113a
SMT-0082)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm. G-120
TABLE OF CONTENTS
INTRODUCTION
INTRODUCTION ........................................................................... OP-1-0A

MESSAGE TO THE OPERATOR .................................................. OP-1-1A.01
IMPORTANT NOTICES................................................................. OP-1-2A.02
GENERAL INFORMATION............................................................ OP-1-3U
GENERAL SAFETY
GENERAL SAFETY ...................................................................... OP-2-0A

GENERAL INFORMATION............................................................ OP-2-1A
TERMINOLOGY ............................................................................ OP-2-2A
OPERATOR'S GENERAL SAFETY GUIDELINES ....................... OP-2-3A.01
SAFETY RESPONSIBILITY OF THE OPERATOR ....................... OP-2-4A.02
QUALIFICATIONS FOR OPERATORS (ANSI/ASME B30.2-1996) ... OP-2-5A.02
GENERAL OPERATING GUIDELINES FOR SAFE OPERATION OP-2-6A.03
GROUNDCREW SAFETY GUIDELINES
GROUNDCREW SAFETY GUIDELINES ...................................... OP-3-0A

AN OPERATING CRANE
CAN BE DANGEROUS TO GROUND PERSONNEL ................... OP-3-1A.01
COMMUNICATION BETWEEN OPERATOR
and GROUNDCREW..................................................................... OP-3-2A
RECOMMEDED SAFETY GUIDELINES FOR GROUNDCREW
and OTHER PERSONNEL ............................................................ OP-3-3A.01
RESPONSIBILITIES FOR THE GROUNDCREW FOR SAFE
OPERATION OF THE CRANE ..................................................... OP-3-4A.01
OPERATOR’S CONTROLS
OPERATOR’S CONTROLS........................................................... OP-4-0A

INTRODUCTION ........................................................................... OP-4-1A.02
CAB CONTROLS (ILLUSTRATION ONLY ................................... OP-4-41G
CAB CONTROLS .......................................................................... OP-4-46F
GROUND CONTROL PANEL........................................................ OP-4-90F
OP-0-1AT-1
TABLE OF CONTENTS
OPERATING PROCEDURES
OPERATING PROCEDURES ....................................................... OP-5-0A

INTRODUCTION ........................................................................... OP-5-1A.02
PRE-OPERATIONAL INSPECTION CHECKS.............................. OP-5-15M
ENGINE START-UP/STOPPING PROCEDURES ........................ OP-5-20O
CRANE WARM-UP PROCEDURE................................................ OP-5-25B.02
STEERING .................................................................................... OP-5-35G.01
DRIVING (TRAVELING) ................................................................ OP-5-40J.02
TRAVERSE (TROLLEY)................................................................ OP-5-50N.01
HOISTING ..................................................................................... OP-5-55I.01
LOAD HANDLING - WITH HOOKS OR STRONGBACK BEAM ... OP-5-70G.03
SHUTDOWN PROCEDURES ....................................................... OP-5-75B.01
TOWING ........................................................................................ OP-5-80A
PLANNED MAINTENANCE
PLANNED MAINTENANCE .......................................................... OP-0-6A

AIR CONDITIONING ..................................................................... OP-6-3A
“C” SPREADER OPTION .............................................................. OP-6-25C
OP-0-1AT-2
SECTION 1
INTRODUCTION
© - 2004 - MI-JACK Products OP-1-0A-1

NOTES

MESSAGE TO THE OPERATOR
(SMT-0071a
WARNING
This machine must be operated by trained personnel only.

Operation by untrained personnel could result in personal
injury or death. OP-148a
You are about to operate the finest MACHINE in the industry.
A great deal of confidence has been placed in you because you were se-
lected to operate such a key piece of equipment. When operating this ma-
chine, keep in mind safety and maintenance. Your skill and attitude (or
lack of) are the most important factors in controlling safety and mainte-
nance costs. A careless or untrained operator can make useless any safe-
ty device installed on the machine. He also can cause damage to the
machine itself.
As you become familiar with the day-to-day operation of this machine, you
will become familiar with its distinctive sound and “feel”. Only you can no-
tice any changes in its operation. If something doesn’t sound right or feel
right, bring it to the attention of your maintenance department. If caught in
time, it may result in savings to your company.
Most importantly, operate your machine in a safe and efficient manner. Be

alert at all times and follow the safety rules and operating procedures as
provided in this manual.
The mark of an experienced operator is safe, efficient, well-thought-out

moves. The responsibility placed on you as an operator of this key piece
of equipment marks you as a professional operator.
Operator instruction is available for present or new operators by contacting

MI-JACK Products, Hazel Crest, Illinois, 60429, (708/596-5200).
© - 2002 - MI-JACK Products OP-1-1A.01-1

IMPORTANT NOTICES
(SMT-0072a
MI-JACK shall have no liability with respect to:
• repairs improperly performed.

• replacement parts improperly installed.
• use of replacement parts or accessories not conforming to MI-
JACK's specifications.
• alterations or modifications not recommended or approved in
writing by MI-JACK. F-157b
As part of MI-JACK Products' on-going program to improve its products

and service, (and their effectiveness in enhancing reliability, performance,
productivity and useful service life of its equipment), MI-JACK reserves
the right to implement product changes and disseminate changes in ser-
vice information without notice or recourse.
SMT-0072a)

IMPORTANT NOTICE REGARDING BRAKING
(SMT-0073-1
A variable distance is required to stop the crane, depending on the

load and speed.
Although it may be possible to stop an automobile traveling at 5 MPH in

just a few feet, a train traveling at the same speed, because of its additional
weight and inertia, requires a much greater distance to stop. Likewise, a
crane, due to its weight and inertia, requires a greater distance to stop than
an automobile. Therefore, the crane's inertial force resulting from its
speed and weight influences how quickly the crane can be stopped, just
like any other vehicle. Because of the crane's gross weight, it cannot be
stopped instantly.
Be sure to allow ample stopping distance when driving to avoid col-

lisions.
150 140 130 120 110 100 90 80 70 60 50 40 30 20 10
33064
33064
WARNING
Working in the area of industrial equipment is dangerous. Cer-

tain inherent risks are associated with industrial machines due
to the nature of their use. Personnel in the area of industrial
machines are subject to certain hazards that cannot be met by
mechanical means but only by the exercise of intelligence,
care, and common sense. It is therefore essential to have per-
sonnel involved in the use and operation of equipment who are
competent, careful, physically and mentally qualified, and
trained in the safe operation of the equipment and the handling
of loads. Failure to do so could result in personal injury or
death. G-113a
SMT-0073-1)

TRAVELIFT® CRANE
(Standard Cab Shown)
11 12
Front View
10
20161
9 8
7
2
4 3 6
5 1
20162
FORWARD Left Side View
1. Drive Wheel 7. Operator's Cab and Controls

2. Location of Hydraulic Pumps 8. Column, Left Rear
and Filters 9. Column, Left Front
3. Diesel Engine 10. Hoist Motor & Brake
4. Left Side Beam 11. Front Top Beam
5. Wheel Guards 12. Trolley
6. Wheel Yoke
© - 2004 - MI-JACK Products OP-1-3U-1

GENERAL DESCRIPTION
(SMT-0158b-6
The TRAVELIFT™ Crane is a rubber tired , mobile, gantry crane. Its four
columns are connected by side beams and top beams. The side beams
support the engine/hydraulics compartment and operator cab.
The top beams are the main load carrying beams. The hoisting and
traverse mechanisms are mounted on the top beams. The trolleys travel
(traverse) along the top beams from end-to-end during load handling.
The front and rear hoists can be operated independently, as well as the
front and rear traverse.
The crane is hydraulically powered through hydraulic piston pumps which

are driven by a diesel engine. Electronic controllers are used to control the
speed and direction of the respective functions. The hydraulic pumps
have a variable output for maximum efficiency.
The Drive System uses two fixed displacement motor and transmission as-
semblies. Power output from the assemblies goes through roller chains
and sprockets to the drive wheels. Dynamic braking, through the drive mo-
tors, is used to stop the machine. Brakes mounted on the drive motors act
as a parking brake.
SMT-0158b-6)
© - 2004 - MI-JACK Products OP-1-3U-2

SECTION 2
GENERAL SAFETY

NOTES

GENERAL INFORMATION
(SMT-0074
Your safety and the safety of others in the work area of the machine is a
direct result of your correct operation of this machine. Know the location,
positions and functions of all the controls. MAKE SURE YOU CHECK ALL
CONTROLS IN A SAFE, CLEAR AREA BEFORE YOU WORK THE MA-
CHINE.
READ THIS MANUAL COMPLETELY AND MAKE SURE YOU UNDER-

STAND THE CONTENTS. Make sure you understand, for example, the
characteristics of speed, stability, brakes, steering, etc., of this machine. If
you have any questions, contact MI-JACK Products, (708) 596-5200. Al-
ways keep this manual with your machine.
It is recommended that you make copies of the safety guidelines in this

manual and put these copies in the work area.
LOCAL LAWS
The safety information in this manual does not replace any other rules or
laws for safety that are used in your area. Know the local rules or laws for
safety. Make sure that your machine has the correct equipment to operate
according to these rules or laws.
USING COMMON SENSE
All safety hazards that can possibly arise cannot be foreseen and noted in
this manual. You must always use common sense and apply the general as
well as the specific safety precautions.
SMT-0074)
© - 2002 - MI-JACK Products, Inc. OP-2-1A - 1

TERMINOLOGY
(SMT-0075
The following terms define the various precautions and notices used in this
manual.
NOTE
“NOTE” is the term used whenever information requires

additional emphasis beyond the standard text.
IMPORTANT
“IMPORTANT” is the term used whenever information

requires special attention to procedures to ensure proper
operation or to prevent possible equipment failure.
CAUTION
“CAUTION” is the term used whenever there is potential for

equipment damage that requires correct procedures/prac-
tices for prevention.
WARNING
“WARNING” is the term used whenever there is a potential

for personal injury or death that requires correct proce-
dures/practices for prevention.
DANGER
“DANGER” is the term used whenever there is an immedi-

ate hazard that cannot be eliminated by design safeguards,
which could result in personal injury or death.
This safety alert symbol indicates important safety mes-

sages in this manual. When you see this symbol, carefully
read the message that follows and be alert to the possibility
of personal injury or death.
SMT-0075)
© - 2002 - MI-JACK Products, Inc. OP-2-2A - 1

OPERATOR'S GENERAL SAFETY GUIDELINES
(SMT-0076
WARNING
Working in the area of industrial equipment is dangerous. Certain

inherent risks are associated with industrial machines due to the
nature of their use. Personnel in the area of industrial machines
are subject to certain hazards that cannot be met by mechanical
means but only by the exercise of intelligence, care, and common
sense. It is therefore essential to have personnel involved in the
use and operation of equipment who are competent, careful,
physically and mentally qualified, and trained in the safe opera-
tion of the equipment and the handling of loads. Failure to do so
could result in personal injury or death. G-113a
It is recommended that you check your federal and state OSHA requirements
for warning and safety devices relating to your application and operating
procedures.
In addition, MI-JACK recommends that operators and operator trainees must

be able to read, write and understand the English language.
SMT-0076)
© - 2002 - MI-JACK Products, Inc. OP-2-3A.01 - 1

SAFETY RESPONSIBILITY OF THE OPERATOR
(SMT-0077b-2
The safety instructions and warnings in this manual, which is shipped with the
machine, provide the most reliable procedures for the safe operation of the
machine. It is your responsibility to see that they are carried out.
Remember, YOU are the person in control of the machine. Do not move it until
YOU know it is safe to do so.
WARNING
Do not move the machine until the surrounding area has been
checked and is clear of personnel and obstructions. Failure to
do so could result in personal injury or death. OP-108b
WARNING
Electrical, mechanical, and hydraulic safety devices have been

installed on this machine to help protect against personal injury
and/or damage to equipment. Under no circumstances should
any attempt be made to disconnect or in any way render any of
these devices inoperative. If a malfunction of any safety device
is discovered to exist, DO NOT operate the machine, immediately
notify appropriate maintenance personnel. Disregarding the
above could result in personal injury or death. G-114a
Proper lighting, safety signs, warning bells, etc., can only ASSIST in preventing
an accident. But YOU, the operator, can PREVENT an accident. YOU, the
operator, must act as airline captain, and be responsible for the personal safety
of yourself and all persons around the machine. When used, the GROUND-
CREW should act as your controller. They can GUIDE you to avoid accidents,
such as advising when the aisles are clear. However, YOU, the operator, have
total responsibility for the safe operation of this machine. You are not to move
it until YOU know it is safe to do so, or have been appropriately signaled by an
appointed ground person.
© - 2002 - MI-JACK Products, Inc. OP-2-4A.02 - 1

Operation of Two-Way Radios
IMPORTANT: To ensure the continued safe operating conditions of the

machine, it is a must that all personnel involved in the operation, mainte-
nance, and service be aware of the possibility of radio frequency interfer-
ence with electronic controllers.
Operation of hand held two way radios and/or electronic devices equipped
with receiving and transmitting antennas, must not be used in the cab of
the operating machine. All antennas must be externally mounted to
prevent interference with the electronic controllers.
WARNING
The use of two way radios or other electronic devices may

interfere with the normal operation of the machines' electronic
controllers. This can result in the unexpected operation of
machine functions which could cause damage to equipment,
possible injury to personnel, or death. OP-182b
Towing
MI-JACK Products does not recommend towing this machine except in

emergencies.
If it is absolutely essential that the machine must be towed, contact

MI-JACK Technical Services.
WARNING
Towing any machine without taking the proper prerequisite

steps could result in damage to equipment and possible per-
sonal injury or death. G-118c
SMT-0077b-2)
OP-2-4A.02 - 2 © - 2002 - MI-JACK Products, Inc.

OP-2-5A.02.fm Page 1 Monday, March 6, 2006 8:32 AM
QUALIFICATIONS FOR OPERATORS (ANSI/ASME B30.2-1996)
NOTE: Regulations and references to non-MI-JACK cranes have been

deleted from the following ANSI/ASME Standards. Italics indicates where
the wording was changed by MI-JACK to be applicable to engine powered
mobile cranes.
Section 2-3.1 - Qualifications for and Conduct of Operators
2-3.1.1 Operators of Cab-Operated and Pulpit-Operated Cranes
a. Cranes shall be operated only by the following qualified personnel:
1. Designated persons;
2. Trainees under the direct supervision of a designated person;
3. Maintenance and test personnel, when it is necessary in the per-

formance of their duties.
b. No one other than personnel specified in para. 2-3.1.1-a. shall enter

a crane cab or pulpit, with the exception of persons such as oilers
and supervisors, whose duties require them to do so, and then only
in the performance of their duties and with the knowledge of the op-
erator or other appointed person.
2-3.1.2 Qualifications for Operators of Cab-Operated and Pulpit-Op-

erated Cranes
a. Operators shall be required by the employer to pass a written or oral

examination and a practical operating examination unless able to
furnish satisfactory evidence of qualifications and experience. Qual-
ifications shall be limited to the specific type equipment for which ex-
amined.
b. Operators and operator trainees shall meet the following physical

qualifications:
1. Have vision of at least 20/30 Snellen in one eye, and 20/50

Snellen in the other, with or without corrective lenses.
2. Be able to distinguish colors, regardless of position of colors, if col-

or differentiation is required for operation.
OP-2-5A.02-1
3. Hearing, with or without hearing aid, must be adequate for a spe-

cific operation.
4. Have sufficient strength, endurance, agility, coordination, and

speed of reaction to meet the demands of equipment operation;
5. Not have evidence of physical defects, or emotional instability that

could render a hazard to the operator or others, or which in the
opinion of the examiner could interfere with the operators perfor-
mance. Evidence of such conditions may be cause for disqualifi-
cation. In such cases, specialized clinical or medical judgments
and tests may be required.
6. Not have evidence of being subject to seizures or loss of physical

control. Evidence of such conditions shall be reason for disquali-
fication. Specialized medical tests may be required to determine
these conditions.
c. Operators and operator trainees should have normal depth percep-

tion, field of vision, reaction time, manual dexterity, coordination, and
no tendencies to dizziness or similar undesirable conditions.
2-3.1.5 Operators of Remote-Operated Cranes.
Cranes shall be operated only by the following qualified personnel:
a. Designated persons
b. Trainees under the direct supervision of a designated person.
c. Maintenance and test personnel, when it is necessary in the perfor-

mance of their duties.
d. Inspectors
2-3.1.6 Qualifications for Operators of Remote Operated Cranes.
The use of remote control equipment involves such a wide variety of

service requirements and conditions that each installation should be
carefully analyzed and operation reviewed at least monthly for the first
six months of operation to determine whether Paragraph 2-3.1.2
should apply.
OP-2-5A.02-2
2-3.1.7 Conduct of Operators
a. The operator shall not engage in any practice that will divert atten-
tion while actually engaged in operating the crane.
b. When physically or otherwise unfit, an operator shall not engage in

the operation of the equipment.
c. The operator shall
1. be familiar with and understand hand signals;
2. respond to signals from the person who is directing the lift, or an

appointed signalperson;
3. be responsible for the lifts when a signalperson or crane follower

is not required as part of the crane operations;
4. open the magnet switch upon request from the person on the
ground, who shall wait for a signal from the operator that the mag-
net is deenergized; and
5. obey a stop signal at all times, no matter who gives it.
d. Each operator shall be responsible for those operations under the

operator’s direct control. Whenever there is doubt as to safety, the
operator shall consult with the supervisor before handling the loads.
e. The operator shall activate the warning device on cab- and remote-
operated cranes, and when provided, on floor-operated cranes
1. before starting the bridge or trolley motion of the crane, and
2. intermittently during travel of the crane when approaching persons

in the path of the load.
f. Before leaving a cab-operated crane unattended, the operator shall

land any attached load, place controllers in the "off" position, and
shut down the engine.
g. The operator shall not start the engine until certain that no worker is
on or adjacent to the crane. If there is a warning sign or lock on the
device, it shall not be energized until the sign or lock is removed by
the person who placed it there, or by an authorized person.
h. Before starting the engine, the operator shall be sure that all control-
lers are in the "off" position.
i. (NOT APPLICABLE)
OP-2-5A.02-3
j. The operator shall be familiar with the equipment and its proper
care. If adjustments or repairs are necessary, or any defects are
known, the operator shall report the same promptly to the appointed
person who shall be responsible for the operation and maintenance
repairs of the crane. The operator shall also notify the next operator
of any remaining uncorrected defects upon changing shifts.
k. (NOT APPLICABLE)
l. Operators of all cranes shall secure them when leaving.
m. (NOT APPLICABLE)
n. Before maintenance personnel perform any maintenance work on

the crane, appropriate personnel shall lock-out, tag-out the main
electrical switch (if applicable) in the de-energized position.
o. All controls shall be tested by the operator before beginning a new

shift. If any controls do not operate properly, they should be adjusted
or repaired before operations are begun.
p. (NOT APPLICABLE)
OP-2-5A.02-4
GENERAL OPERATING GUIDELINES FOR SAFE OPERATION
(SMT-0078a
The following guidelines are to alert you to conditions or situations that

could cause an accident. Review each one thoroughly so you will be able
to recognize and avoid possible hazards or avoid an accident when haz-
ards cannot be eliminated.
• Be familiar with and understand the safety information in the manuals

and on the machine decals prior to operating it. Also, refer to other safe-
ty guidelines in Groundcrew Safety Guidelines and Operating Proce-
dures.
IMPORTANT: Always adhere to YOUR employer's standard safe oper-

ating procedures as they relate to your particular operation.
WARNING
Be familiar with and understand the safety information in

the machine manuals and on the machine prior to operat-
ing. Failure to read this information could result in injury
to personnel and/or damage to the machine. G-109c
33023

• You must be instructed in the operation and daily care of the machine pri-
or to operating. Ask your supervisor for operating instructions if you
have not had such.
IMPORTANT: Be extremely careful if you do not normally operate this

machine. Reorient yourself to it prior to starting, and then proceed slow-
ly. However, you must NOT operate this piece of equipment without prior
and proper instruction.
WARNING
Never operate the machine without proper instructions. Ig-

norance to the operational characteristics and limitations
can lead to equipment damage, personal injury, or death.
OP-100-R2
33018

• Wear the correct safety equipment; Safety glasses, hardhat, safety
shoes/boots as established by your employer's safety policy. DO NOT
wear loose clothing. If required, obtain additional safety equipment
which may include but is not limited to; Ear protection, reflective clothing
and gloves.
WARNING
Wear the correct Personal Protective

Equipment (PPE). DO NOT wear loose
clothing. If required, obtain additional
PPE , which may include but is not limit-
ed to; hard hat, safety shoes, ear protec-
tion, reflective clothing, safety goggles
and safety gloves. Failure to do so could
result in personal injury or death.G-106e
33002
• When going up and down ladders, always face the ladder and use both
hands. Use both hands when getting on and off the machine. Do not
carry objects in one hand while climbing up or down.
WARNING
When going up and down ladders,

always face the ladder and use
both hands. Also, use both hands
when getting on and off the ma-
chine. Do not use one hand to car-
ry objects while climbing up or
down. Failure to use both hands,
or attempting to carry an object in
your hand while climbing up or
down, could result in a fall caus-
ing personal injury or death. G-101d
33005
• Make sure that you check all controls in a safe, clear area before you
work the machine.
• Do not travel the crane with lifting slings, chains or straps attached to
the trolleys, spreader, etc. Hooks can catch personnel, containers or
other items causing personnel injury, crane damage or imbalance.

• You should start slowly, applying what you learned during your instruc-
tions, and allow your operating speed to increase as you become more
familiar with the machine and its characteristics.
33060
• Do not work a track unless it has been protected by a "blue flag" or some
other recognizable indicator. Know your employer's policies!
WARNING
To prevent damage to the equipment and injury to person-

nel, be sure that the "blue flag" is placed over the track
before working. G-110
33024

• Never operate the crane when railroad cars are being switched under-
neath the crane.
33025
• Always park the machine in a safe area away from railroad tracks and
truck lanes.
CAUTION
To prevent damage to the crane, move the crane away

from the tracks to a safe area when it is not being oper-
ated. G-112
33026

• Know where the fire extinguisher is located and how to use it. Make sure
it is fully charged.
WARNING
Know where the fire extin-

guisher is located and how to
use it. Failure to do so could
result in personal injury or
death.G-102a
33020
• Keep your hands, feet and clothing away from moving parts such as
gears, drums, chains, wire rope, and sheaves during operation.
WARNING
Keep your hands, feet and clothing away from moving

parts such as gears, drums, chains, wire rope, and
sheaves during operation. Failure to do so could result in
personal injury or death. G-104-R2
33021

• All walking surfaces (steps, ladders, etc.) and hand railings must be
free of ice, grease, oil, or other materials that could cause or contribute
to a slip or fall by personnel.
WARNING
All walking surfaces (steps, ladders, etc.) and hand rail-

ings must be free of ice, grease, oil, or other materials that
could cause or contribute to a slip or fall by personnel
resulting in personal injury or death G-105a
33022

DANGER
NEVER operate the machine under electrical power lines.

Electrical energy under high voltage can discharge to ground
through the machine without direct contact with the ma-
chine’s structure resulting in personal injury or death. OP-110bc
Minimum clearances from energized power lines or other power sources

must be kept. Refer to the following illustration from OSHA recommended
Electrical Conductor Clearance Chart. When in doubt, contact your local
Electrical Power Utility Company FIRST! If the voltage is unknown, do not
operate within 45 ft. of the energized part.
NOTE: Where local or other applicable safety codes or regulations specify

greater clearance distances, the local or other applicable safety codes or
regulations shall apply.
IMPORTANT: If electricity does discharge through the machine, REMAIN

IN THE CAB. DO NOT PERMIT ANY PERSONNEL TO COME IN CON-
TACT WITH THE MACHINE’S STRUCTURE.
MINIMUM SAFE CLEARANCE
0 TO 50,000 VOLTS 10 FT.(3.1 M)

50,000 TO 200,000 VOLTS 15 FT.(4.6 M)
200,000 TO 350,000 VOLTS 20 FT.(6.1 M)
350,000 TO 500,000 VOLTS 25 FT.(7.6 M)
500,000 TO 750,000 VOLTS 35 FT.(10.7 M)
750,000 TO 1,000,000 VOLTS 45 FT.13.7 M)
13.7m10.7m7.6m6.1m4.6m 3.1m
45’
13.7M 35’ 25’ 20’ 15’ 10’
13.7m 10.7m 7.6m 6.1m 4.6m 3.1m
20090.TIF 33124.TIF

DANGER
On machines equipped with magnetic lifting devices, the

electrical generating system for the magnets must be
checked before each shift and anytime the machine is to be
started. Failure of the generating system during lifting oper-
ations will cause dropped loads which could result in per-
sonnel injury or death. OP-211

SECTION 3
GROUNDCREW SAFETY GUIDELINES

NOTES

AN OPERATING CRANE
CAN BE DANGEROUS TO GROUND PERSONNEL
If ground persons are used in conjunction with the operation of this

crane, MI-JACK does not recommend nor suggest where the ground-
crew (hooker, helper, etc.) should be positioned, stationed, or located
during operation of the crane. Only the operating entity should decide
where the groundcrew personnel should be, based upon the applica-
tion, yard design, and the safety rules of the company for which those
personnel are working when in the vicinity of the crane.
MI-JACK only recommends that all of the groundcrew be within sight

of the operator before the crane is operated (drive, hoist, traverse,
steered) and that they stay in communication with the operator while
the crane or any part of it is in motion. If any ground personnel has to
move out of the operator's sight, the operator should re-establish
communication with all personnel before operating the crane, even if
the "All Clear for Moving the Crane" signal has been given.
ANSI Qualifications for crane operators are printed within this manual.
MI-JACK recommends that operators be so qualified and that all
groundcrew and maintenance personnel be similarly selected to en-
hance safe operation of the crane.
It is recommended that you check your Federal or State OSHA require-

ments for warning and safety devices relating to your application and
operating procedures. F-185
WARNING
When operating this crane, if any abnormal condition in its

operation occurs, move the crane to a safe parking area, if
possible, and when safe to do so, shut down the crane and
notify appropriate maintenance personnel. Failure to do so
could result in personal injury or death. OP-168b
© • 2002 • MI-JACK Products, Inc. OP-3-1A.01 - 1

COMMUNICATION BETWEEN OPERATOR and GROUNDCREW
(SMT-0079a-2
All directional references given relate to the machine. Refer to the "OPERATING
PROCEDURES" section for machine direction orientation.
If ground persons are used in conjunction with the operation of this crane,
clear and precise communication between the operator and the groundcrew is
a must for safe and proficient crane operation.
The following signals are normally used with crane operation. The operator
and groundcrew should review them together prior to operating to ensure
accurate communication and to establish an "ALL CLEAR FOR MOVING THE
MACHINE" signal.
17004
SMT-0079a-2)
© • 2002 • MI-JACK Products, Inc. OP-3-2A - 1

RECOMMENDED SAFETY GUIDELINES FOR GROUNDCREW AND
OTHER PERSONNEL
(SMT-0080-1
• The operator and the groundcrew (if used) must be in constant communi-
cation with each other at all times. Review the communication system to
be used before starting. Both persons must know the proper hand signals
for each movement of the machine or load.
• If ground persons are utilized in conjunction with the operation of this

machine, do not move the machine without the proper signal from your
groundcrew. The groundcrew must be in the operator's view at all times.
The operator must stop the machine if the groundcrew disappears from his
view.
33003
• Know and understand the arrangements for movement of trucks, ma-

chines, personnel, etc. on your job. Be ALERT at all times.
• Stand clear of the spreader (if equipped) during length adjustment.
• Keep the machine's operating area free from debris that could cause tire
damage that may result in a tire blow-out and possible damage to equip-
ment.
33066

• The operator and the groundcrew are to ensure that ALL ground per-
sonnel are out of the machine's entire hoist working area before hoist-
ing a load and that the area remains clear of personnel until the load is
lowered safely to a suitable resting place.
33006
• Never lift, lower, or move any person on the spreader, load, or attachment.
SMT-0080-1)
DANGER
NEVER lift, lower, or move any

person on the spreader, load,
or attachment. Movement of
these items with personnel
riding on them can cause seri-
ous injury or death. OP-116
33009
OP-3-3A.01 - 2 © • 2002 • MI-JACK Products, Inc.

RESPONSIBILITIES OF THE GROUNDCREW FOR SAFE OPERATION
OF THE CRANE
(SMT-0081-1
When groundcrew personnel are used in conjunction with the operation of

this machine, they are the eyes and ears of the machine operator. The
machine, like any other equipment, can be DANGEROUS if not operated
properly. Before working around the machine, the groundcrew is to be
properly trained and are to understand all of their responsibilities related
to the machine's operation.
The following are suggested responsibilities. There may be more. It is

the responsibility of the equipment user to establish the policies.
IMPORTANT: It is the employer's responsibility to implement all

precautions to provide the employee(s) with all safety devices or
means that may be necessary or be required for any particular use:
Operations, Set-up or Service.
1. Wear proper protective clothing and equipment

when working around the machine; hard hat,
safety shoes, safety glasses, hearing protec-
tion, reflective vest or reflective clothing,
gloves, etc. as established by your employer's
safety policy.
33002
2. Give proper operation signals. A decal is on the crane that illustrates

acceptable hand signals.
33001

3. Be sure you check with the operator and make certain that he under-
stands the safety guidelines for groundcrew.
33007
4. Do not give the operator a signal to move the machine until you and
other ground personnel are clear of all moving parts.
5. Know at all times where other groundcrew members are before signaling
the operator.
DON'T FORGET THE

OTHER PERSON!
33003

6. The groundcrew should be aware of other people in the area and warn them
that the crane is approaching them.
33015
7. Never ride on any part of the crane other than designated seating areas.
NO RIDING!
33005
8. Never ride on the load, or hang from any attachment.
33009

9. Do not get closer than 6 ft.(2 M) of the wheels of the crane. Stay clear
of the turning circle of the steer wheels.
6FT.
(2 M)
MIN.
WHEEL TURNING CIRCLE

33014
TOO CLOSE!
33011
10. Never walk under the side beams of the crane or pass between the
wheels and structures under the side beams.
33065
WARNING
Never walk under the side beams of the crane or pass

between the wheels and structures under the side beams.
This creates an unsafe condition that could lead to person-
nel injury or death. OP-199
SMT-0081-1)
11. Do not turn your back on the crane. Always face it and keep it in full
view at all times.
33017
12. Never walk or stand under suspended loads. If a load will be traveling
over you, move a safe distance away.
33006

13. Do not stand between the crane and other obstructions or equipment.
33008
14. Always stay clear of "blind spots" and stand in full view of the operator or
be in constant radio communication with him.
33012
DANGER
Stacks of containers or materials can cause "blind spots" for

the operator. It is essential, for safe operation, that the
groundcrew stay clear of "blind spots" and stay within sight of
the operator at all times. Never walk in the aisleways of the
crane. Disregarding the above could result in personal injury
or death. OP-183-1a

15. Always use the proper and safe hooking devices and methods for the
particular load being handled.
IMPORTANT: Do not travel crane extended distances with lifting slings,

chains or straps attached to trolleys or attachments. Hooks can catch
personnel, containers or other items causing personal injury or imbal-
ance.
90-33-013-0
16. Inspect cable, chains, slings, etc. before and during use.
90-33-016-0

SECTION 4
OPERATOR’S CONTROLS

NOTES

INTRODUCTION
The following illustrations and explanations point out and describe the controls
and indicators used by the operator. The indicators may be lights or sounding
devices.
The controls may be buttons, levers, knobs or keys. Each item is identified
by a number that matches its description and function.
IMPORTANT: Instrument readings, as indicated in this manual are based on

normal operating conditions. If the actual readings are different than indicated
as proper, shut down the machine and engine as soon as it is safe to do so
and report the situation to appropriate maintenance personnel.
WARNING
Do not attempt to operate this machine before knowing and

understanding all of the safety and operating information in this
manual. Doing so could result in personal injury or death. G-121-1a

CAB CONTROLS
1 2 3 4 5 7 8 9 10 11
6
18 29
17
28
16
15 14 13 12 16095.TIF
19
16094.TIF
21 22 27
26
25
20
24
23
16075 18937
© • 2006 • MI-JACK Products, Inc. OP-4-41G - 1

OP-4-46F.fm Page 1 Monday, March 6, 2006 9:08 AM
CAB CONTROLS
1. HOURMETER
Records engine operating time.
2. VOLTMETER
Indicates system voltage whenever the ignition switch is turned to

the ON position.
3. FUEL GAUGE
The fuel gauge indicates the fuel level.
4. ENGINE OIL PRESSURE
Indicates engine oil pressure.
NOTE: Automatic shut-down of the engine will occur if the oil pres-
sure falls below minimum limits.
5. ENGINE COOLANT TEMPERATURE
Indicates the temperature of the engine cooling system.
NOTE: Automatic shut-down of the engine will occur if coolant tem-

perature exceeds maximum limits.
NOTE: Automatic shut-down of the engine will occur if coolant level

is too low.
6. ENGINE MAINTENANCE LIGHT
This light will flash in the key "ON" position when the end of the oil
change interval is reached.
7. DASH LIGHTS SWITCH
Controls the instrument panels and the gauge panel lights.
8. DRIVE LIGHTS SWITCH (if equipped)
Activates the drive lights. (These lights illuminate the front and rear
of the crane).
9. WORK LIGHTS SWITCH (if equipped)
Activates the work lights. (These lights illuminate the work area un-
der the crane).
10. FLOOD LIGHTS SWITCH (if equipped)
Activates the flood lights. (These lights illuminate the general ma-
chine area).
© - 2006 - MI-JACK Products OP-4-46F-1

11. ECS FAULT RESET BUTTON
Pressing this button will clear any fault stored in the ECS. If the func-
tion faults again immediately after clearing the fault, service person-
nel will need to be notified.
12. IGNITION SWITCH
Used to start the engine, turn the power on and off for cab functions
and to turn the engine off.
IMPORTANT: If equipped with a “Wait To Start” light, do not turn the

key to the start position until the "Wait To Start" light turns off.
IMPORTANT: Do not engage the starter for more than 30 seconds

at a time. If the engine does not start within the first 30 seconds, wait
a few minutes for the starter to cool before attempting a restart. The
starter can be damaged if it becomes too hot!
NOTE: Turning the key to the OFF position shuts down the engine
and turns off the electrical circuits.
IMPORTANT: Switch the engine to Low RPM and allow it to idle for
about 3 - 5 minutes before shutting down the engine.
13. RPM HI-LO SWITCH
Used for selecting either "low" or "high" engine speed. The machine
should always be operated with the engine at high RPM.
NOTE: The engine will automatically operate at low RPM until the
engine coolant reaches minimum operating temperatures, even if
HIGH is selected.
14. WIPER SWITCH
Used to operate the wiper/washer on the cab windshield.
15. ECS (Electronic Control System) SYSTEM FAULT INDICATOR

LIGHT
When this light turns ON, all functions controlled by the ECS (hoist,
gantry/drive, and trolley) will be disabled.
16. WAIT TO START LIGHT/COLD START BUTTON
If the machine is equipped with a “Wait to start light”, when the ig-
nition key is turned to the "ON" position, the "Wait To Start" light will
illuminate indicating the electric heater starting aid is operating. DO
NOT turn the key to the start position until the light turns "OFF"
If the machine is equipped with a “Cold start button”, when pressed

while the engine is cranking, a measured amount of starting fluid is
injected into the engine for cold weather starting. Refer to "Operat-
ing Procedures" for precautions.

NOTE: Machines with Cummins engines and cold start will be

equipped with a “Wait to start light”. Machines with Detroit engines
and cold start will be equipped with a “Cold start button”.
17. STOP ENGINE LIGHT (SEL)
Illuminates when the Engine Control Module (ECM) has detected a

major fault that can damage the engine. This light will flash to warn
the operator of an impending shutdown event, and the engine will
shut down.
IMPORTANT: When this light flashes you must:
a. Lower and secure the load immediately!

b. Turn the key switch to the off position.
WARNING
Always lower and secure the load immediately when

the warning light flashes. Failure to do so can result in
dropped loads, damage to equipment, personal injury
or death. OP-209 a
18. CHECK ENGINE LIGHT
If monitored engine conditions such as: coolant temperature, oil

pressure, coolant level, etc., are operating outside of calibrated lim-
its, the “Check Engine” light will illuminate.
IMPORTANT: When this light illuminates, lower and secure all

loads, shut down the engine and notify maintenance personnel. DO
NOT attempt to lift any loads when this light is illuminated.
IMPORTANT: Continued operation with the "Check Engine" light il-

luminated will result in engine shut down.
WARNING
Always lower and secure the load when the CHECK EN-
GINE light illuminates. Also, DO NOT attempt to lift any
loads when this light is illuminated. Failure to lower the
load or attempting to lift a load when this light is illumi-
nated can result in dropped loads, damage to equip-
ment personal injury or death. OP-209 a-1

19. DRIVE/GANTRY CONTROLLER PEDAL
This controller pedal provides the operator with full proportional

drive/gantry speed control. The greater the movement of the pedal,
the greater the drive/gantry speed. When the pedal is released, it
will return to its original position and the drive/gantry motors will dy-
namically stop the crane. Once stopped, the parking brakes will ap-
ply automatically. The park brakes will release whenever the
controller pedal is pressed.
20. EMERGENCY STOP BUTTON
Used only for an emergency stop. When depressed, the engine and
all functions will stop.
NOTE: Before attempting to restart the engine, pull up the emergen-

cy stop button to reset the system.
IMPORTANT: The emergency stop button must not be used for nor-
mal shutdown. Regular use of the emergency stop button to shut-
down the engine will lead to shortened engine and machine life.
21. FRONT TRAVERSE CONTROLLER
This is a proportional controller to control the speed and direction of

the front trolley. Push the controller forward, the trolley will traverse
AWAY from the operator. Pull the controller backwards, the trolley
will come TOWARD the operator. The trolley speed is proportional
to the amount of deflection of the controller.
22. REAR TRAVERSE CONTROLLER
The operation of the rear traverse is identical to the front.
23. HORN BUTTON
Activates the horn when pressed.
24. DRIVE SELECTOR
The drive selector selects the drive direction of the crane for either
forward or reverse.
NOTE: The drive selector should always be in neutral (center posi-

tion) whenever the crane is not driving.

25. STEER CONTROL
Used to steer the crane towards the “crane left” or “crane right”.
NOTE: The crane will steer in the direction the steer switch is moved
and the amount of steer correction is dependent on how long the
switch is held. The steer wheels do not automatically return to the
in-line (0°) centered position when the switch is released. After a
steer correction has been made, an equal and opposite amount of
steer correction is required to re-center the steer wheels.
26. FRONT HOIST CONTROLLER
This is a proportional controller and controls the speed and direction

of the front hoist. Push the controller forward to hoist DOWN and
pull the controller backwards to hoist UP. Hoist speed is proportion-
al to the amount of deflection of the controller.
27. REAR HOIST CONTROLLER
The operation of the rear hoist is identical to the front.
28. SPREADER STOP CONTROL
Pressing the red STOP control will de-energize the motor/pump,

stopping all spreader functions.
NOTE: The STOP control will illuminate whenever the machine key
switch is in the ON position.
29. SPREADER START CONTROL
Pressing the green START control energizes the spreader motor/

pump.
NOTE: The spreader motor/pump must be running before any

spreader function will operate.
NOTE: The START control will illuminate whenever the spreader

motor/pump is energized.

GROUND CONTROL PANEL
05655
1. ENGINE START/STARTER LOCKOUT SWITCH
Used to isolate the cab engine start so that it is not operational. The
start lockout switch is equipped with a lockout - tagout system. When
the bar is locked across the switch, the engine cannot be started.
© • 2003 • MI-JACK Products, Inc. OP-4-90F - 1

SECTION 5
OPERATING PROCEDURES

NOTES

INTRODUCTION
(SMT-0083-1a
There are certain operating procedures for the crane that must be followed for
safe, efficient operation. These procedures are simple, yet important. They
are based on common sense and incorporate the design characteristics of the
crane.
CAUTION
This crane is capable of multiple-function operation while

traveling. Extreme caution must be exercised by the operator
to ensure proper clearances at all times to avoid collisions.
While operating, your primary concern should be to safely steer
and stop the crane. OP-184
IMPORTANT: Be sure you follow the start-up and warm-up procedures when
placing the crane into service.
NOTE: The crane should be operated with the engine at high RPM. Otherwise,
the functions may not operate as intended.
WARNING
Electrical, mechanical, and hydraulic safety devices have been

installed on this machine to help protect against personal injury
and/or damage to equipment. Under no circumstances should any
attempt be made to disconnect or in any way render any of these
devices inoperative. If a malfunction of any safety device is
discovered to exist, DO NOT operate the machine. Immediately
notify appropriate maintenance personnel. Failure to do so could
result in personal injury or death. G-114a
© -2004 - MI-JACK Products, Inc. OP-5-1A.02 - 1

AN OPERATING CRANE
CAN BE DANGEROUS TO GROUND PERSONNEL
If ground persons are used in conjunction with the operation of this

crane, MI-JACK does not recommend nor suggest where the ground-
crew (hooker, helper, etc.) should be positioned, stationed, or located
during operation of the crane. Only the operating entity should decide
where the groundcrew personnel should be, based upon the applica-
tion, yard design, and the safety rules of the company for which those
personnel are working when in the vicinity of the crane.
MI-JACK only recommends that all of the groundcrew be within sight of

the operator before the crane is operated (drive, hoist, traverse,
steered) and that they stay in communication with the operator while
the crane or any part of it is in motion. If any ground personnel has to
move out of the operator's sight, the operator should reestablish
communication with all personnel before operating the crane, even if
the "All Clear for Moving the Crane" signal has been given.
ANSI Qualifications for crane operators are printed within this manual.
MI-JACK recommends that operators be so qualified and that all
groundcrew and maintenance personnel be similarly selected to
enhance safe operation of the crane.
It is recommended that you check your Federal or State OSHA require-

ments for warning and safety devices relating to your application and
operating procedures. F-185
WARNING
When operating this crane, if any abnormal condition in its

operation occurs, move the crane to a safe parking area, if
possible, and when safe to do so, shut down the crane and
notify appropriate maintenance personnel. Failure to do so
could result in personal injury or death. OP-168b
OP-5-1A.02 - 2 © - 2004 - MI-JACK Products, Inc.

PRE-OPERATIONAL INSPECTION CHECKS
(SMT-0084-11
Certain inspections are to be performed prior to each shift. You must

know how to properly do these.
NOTE: These inspections may be performed by either the maintenance

personnel or by you, the operator. In either case, it is your responsibility
to be sure that the crane is ready for operation prior to starting.
If maintenance tasks are to be performed by you, refer to the appropriate

service manual for your crane. Otherwise, report any abnormal condition
to appropriate persons.
The following inspections shall be performed prior to each shift:
Prior to starting engine:
Air Cleaner ................... Inspect for damage. Check visual indicator.

(Optional)
Engine Crankcase ........ Check oil level
Radiator ........................ Check coolant level
Hydraulic Reservoir ....... Check Oil Level
Fuel Tank ..................... Check for full tank
Tires & Wheels ............. Check general condition
Operator's Cab ............. Clean thoroughly, including windows
Fire Extinguisher .......... Check for full charge
Steering ........................ Visually check wheels for proper alignment
NOTE: When the steer wheels are turned
straight, both steer wheels should be straight.
Fluid Leaks .................. Visually check for fluid leaks
Structure ...................... Visually inspect all ladders, stairs, platforms,
catwalks and railings for cleanliness.
Visually inspect all structural connections,
ladders, stairs, platforms, catwalks and railings
for obvious damage and missing or loose fasten-
ers.
Visually examine structural members for dam-
age, deformation and alignment.
Check the wheelguards for signs of impact.
Wire Rope .................... Visually inspect rope for any gross damage such
as distortion, general corrosion, broken or cut
strands and broken wires.
© -2004 - MI-JACK Products, Inc. OP-5-15M - 1

After starting engine but prior to operating:
Operator's Controls ....... Check all controls and all crane functions for
proper operation
Operator's Gauges ........ Check that all gauges are indicating proper
operation
Steering ........................ Check for proper operation.
Lights ........................... Check work & drive lights for proper operation. (If
equipped)
Warning Devices .......... Check horn, strobe lights, & travel alarm for
proper operation
Windshield Wipers ....... Check for proper operation
IMPORTANT: If any of the preceeding require attention, notify the

head of maintenance immediately and do not operate the equipment
until it is inspected and approved for operation.
PRE-OPERATIONAL INSPECTION PROCEDURES
Engine Oil Level -
The oil level must be checked prior to starting the engine.
NOTE: A 15 minute drain back time is required if the engine has been
running.
The oil level must be maintained between the “F” (full) mark and the “L”
(low) mark, but as close to the “F” mark as possible.
NOTE: The markings may differ on various dipsticks.
CAUTION
Never operate the engine with the oil level below the "L"
(low) mark or above the "F" (full) mark. Refer to the engine's
OPERATION and MAINTENANCE manual for detailed engine
service. OP-137-R1
33041
OP-5-15M - 2 © - 2004 - MI-JACK Products, Inc.

Engine Coolant Level -
The coolant level can be visually checked by looking at the sight glass
on the coolant recovery tank (if equipped with recovery tank).
NOTE: Check the radiator level in upper radiator tank if no recovery

tank is present.
The level should be approximately at the halfway point with the engine
cold.
NOTE: If the engine is hot, the level will be higher than when it is cold.
WARNING
Do NOT remove the radiator cap or the filler cap if the engine
is hot. The coolant will be under pressure and can escape with
explosive force causing possible personal injury or death. To
prevent burns, remove the radiator cap or filler cap only when
the engine is cool. M-111-R4
33042

Hydraulic Oil Level -
The hydraulic oil reservoir is located in the engine compartment. The

oil level is to be checked with the engine turned OFF. The oil level
should be at the full mark. Should additional oil be required, clean
from around the filler cap, and use only clean oil from a clean con-
tainer. After the engine has been started and allowed to warm up,
recheck the level with the engine running. It must be within the sight
glass.
FULL
LEVEL
22043
Leaks -
Do a "walk around" visual inspection to look for any fluid leaks (cool-
ant, fuel, engine oil or hydraulic oil). Leaks are to include spots on the
ground, fluids running down columns, oil leaking from transmissions
and excessive fluids on components in the engine compartment. All
leaks must be reported to appropriate maintenance personnel prior to
operating.
33050

WARNING
The hydraulic system operates at a very high pressure.

Hydraulic oil, even from a very small leak, can go through
skin and cause serious injury. When checking for leaks, DO
NOT USE YOUR HANDS; use a piece of paper. If hydraulic
oil goes through your skin, get prompt medical attention.
M-132-R1
33054
Fuel Tank -
Fill with diesel fuel as specified by the engine manual at the end of each
shift.
33044

Structural Joints -
Visually inspect the structural joints for missing bolts and capscrews
or any structural cracks. Do not operate the crane with missing
fasteners, structural cracks, signs of impact.
33046
Tires -
Visually inspect the tires for low air pressure and damage to the tread
and side walls. If a tire looks suspect, appropriate maintenance
personnel should thoroughly check it prior to further operation.
33047

Tire Safety
Tires contain tremendous explosive energy. A large tire can contain over
one million foot-pounds of energy when inflated! A tire with 100 psi of
pressure contains approximately eight times its own volume of air!
WARNING
Do not service tires and rims unless qualified to do so.

Improper rim and tire installation or assembly can cause or
contribute to the tire exploding. Serious injury or death can
result. M-114
DANGER
Defective rim components or improper servicing of a tire could

cause its energy to be released instantaneously! This could
propel tire and wheel parts out with deadly force causing
serious injury or death! M-244a
33061.TIF

Steering Alignment (if equipped) -
With the steer wheels both facing directly straight ahead, visually
check that the left rear wheel is in-line with the left front wheel. Then
check that the right rear wheel is visually in-line with the right front
wheel. If this is not the case, the steering is out of alignment. Notify
the appropriate maintenance personnel to have it corrected.
WARNING
Operating the crane with the steering out of alignment can

create structural stresses that can cause damage to the
crane, possibly resulting in structural failure that could cause
serious injury or death. OP-170a
33057
Wheel Guards -
Visually check the wheel guards for loose or missing retaining

capscrews or signs of impact. If there are any signs of impact, have
the crane inspected by appropriate personnel before operating.
18557

Operator's Cab -
Clean thoroughly after each shift, including the windows. Pick up all
loose clothing and other personal articles. Properly dispose of all
trash. See the "Planned Maintenance" section in this manual for
specific instructions on cleaning cab insulation and instrument panels.
33027
33028

Fire Extinguisher -
Check for fully charged condition. If the fire extinguisher has been
discharged, notify the appropriate person.
33048
Lights -
Check the work lights (if equipped), drive lights (if equipped), and cab
interior lights for proper operation, especially if working at night. Notify
the appropriate maintenance personnel if discrepancies exist.
33049

Warning Devices -
Warning devices are to alert ground personnel of the crane's move-

ment. Be sure the horn, strobe lights, and travel alarm are operating
properly. The ignition key must be in the ON position to check the
horn and the engine running to check the strobe lights. To check the
travel alarm, a direction of travel must be selected and the drive pedal
depressed.
IMPORTANT: Make sure the travel path is clear before moving.
33053
Windshield Wipers -
Check the windshield wipers for proper operation.
NOTE: Do not run the windshield wipers for an extended period on a

dry windshield.
33051

Operator's Controls -
Check the operator's control levers for smooth operation. There should
not be any binding or loose connections noted. Notify the appropriate
maintenance personnel if any of these are not OK.
SMT-0084-11)
18942
Typical Operator's Control Consoles

OP-5-20O.fm Page 1 Monday, March 6, 2006 9:56 AM
ENGINE START-UP/STOPPING
(SMT-0085a-1
Do not attempt to start the engine if the machine has been indicated to be
inoperable by any means, such as a tag, disconnected power, or the tag
out/ lock out procedure. If in doubt, contact the maintenance supervisor.
18943
05655
WARNING
Do not attempt to start the engine if the machine has been

locked-out/tagged-out or indicated in any other way that it is
not to be started. Doing so can result in personal injury and/
or damage to the equipment. If in doubt, contact the mainte-
nance supervisor. OP-115f
For maximum engine protection and easier starting:
1. Keep the batteries fully charged.
2. Keep the fuel clean and free of water.
3. Change the crankcase oil to the recommended viscosity for the air
temperature.
NOTE: When temperatures are below 50° F (10° C), it is recom-

mended that the engine heater be used for easier starting. Addition-
ally, the cold start system may be used according to instructions (if
equipped).
© - 2004 - MI-JACK Products OP-5-20O-1

Start-up Procedure: For machines equipped with Cummins engine only.
1. Adjust the seat.
2. Check that all controls are in their neutral position.
3. Set the RPM select switch to LOW RPM.
4. Sound the horn.
WARNING
Sound the horn to alert all personnel in the area before

starting the engine. Make sure everyone is clear of the
crane and the engine compartment. Failure to do so
could result in personal injury or death. OP-106-R3
5. Turn the key switch to the ON position.
6. Wait for the red "Wait to Start" light on the instrument panel to turn
OFF, then turn the key to the start position.
IMPORTANT: Do not engage the starter for more than 30 seconds at

a time. Heat damage can be caused to the starting motor. If the en-
gine does not start within the first 30 seconds, wait one or two minutes
before making another start.
NOTE: This machine is equipped with an electric cold start aid. The
red "Wait to Start" light illuminates while the electric heater is heating
up and turns off when the electric heater is hot enough to attempt
starting the engine. DO NOT use starting fluid at any time.
WARNING
This machine is equipped with an electric cold start aid.

DO NOT use starting fluid at any time. Using starting flu-
id on machines equipped with electric cold start aids can
result in explosions and/or fires, causing serious bodily
harm or death. OP-234
7. Warm up the engine. Run the engine at low RPM for at least five min-
utes, to allow the coolant temperature to rise, before putting any load
on the engine.
NOTE: The engine will automatically operate at low RPM, even if

high RPM is selected, until engine coolant is sufficiently warm.
SMT-0085a-1)

Start-up Procedure: For machines equipped with Detroit engine only.
1. Adjust the seat.
2. Check that all controls are in their neutral position.
3. Set the RPM select switch to LOW RPM.
4. Sound the horn.
WARNING
Sound the horn to alert all personnel in the area before

starting the engine. Make sure everyone is clear of the
crane and the engine compartment. Failure to do so
could result in personal injury or death. OP-106-R3
5. Turn the key switch to the START position and hold to start the en-
gine.
IMPORTANT: Do not engage the starter for more than 30 seconds at

a time. Heat damage can be caused to the starting motor. If the en-
gine does not start within the first 30 seconds, wait one or two minutes
before making another start.
NOTE: When temperatures are below 50°F (10° C), the optional cold
start system, if provided, may be used. While cranking the engine,
press the cold start button for no longer than one second.
IMPORTANT: The starting fluid will only be discharged while the en-
gine is cranking. A metered amount of starting fluid is discharged into
the engine each time the cold start button is pressed. Do not press
the button more than once for each 10 seconds during the start at-
tempt, to avoid engine vapor lock.
WARNING
When using starting fluid, handle according

to instructions on its container. DO NOT
smoke while using starting fluid. Avoid acci-
dentally spraying it on hot objects or in areas
where sparks or electrical arcing may occur.
Explosions and/or fires can result, causing
33035
serious bodily harm or death. OP-132-d
6. Warm up the engine. Run the engine at low RPM for at least five min-
utes, to allow the coolant temperature to rise, before putting any load
on the engine.

Stopping The Engine
NOTE: If shutting down for the day, refer to the "Shutdown Proce-
dures" at the end of this section.
1. Switch the engine to LOW RPM and allow the engine to idle for 3 -
5 minutes.
CAUTION
The engine must be idled 3 to 5 minutes before shutting

down to allow the engine to cool slowly and evenly. Oth-
erwise, severe damage to the engine or related compo-
nents can result. OP-124
2. Turn the key switch to the OFF position to turn off all electrical con-
trol circuits.
NOTE: If the key switch is left ON, the batteries will discharge.
IMPORTANT: Ensure that all controls are in NEUTRAL and switch-

es are OFF before leaving the cab.
3. If the engine will be stopped for a prolonged period during cold

weather, plug in the engine block heater and/or hydraulic oil tank
heater (if equipped).
Emergency Shutdown
The emergency shut down system provides a means of shutting down

the crane in the event of an emergency.
1. Press the emergency stop button.
2. Turn the ignition switch to the OFF position.
NOTE: When engine stops completely, pull the emergency stop but-
ton out to reset the system. If the system is not reset, the engine will
not restart when cranked.
NOTE: The emergency stop button is for "emergency only" and

must not be used when routinely shutting down the crane. Always
follow the procedure for stopping the engine.

USING BOOSTER BATTERIES OR STARTING GENERATORS

(SMT-0088a
WARNING
Booster batteries should only be connected by personnel

who have been specifically trained in their proper use.
Failure to connect booster batteries correctly could re-
sult in severe personal injury and/or damage to equip-
ment. M-217
If the batteries on the machine are weak or discharged, use booster

batteries or a starting generator to start the engine.
IMPORTANT: DO NOT try to start the engine by towing or pushing.
1. Chock the wheels and move all the electrical controls to the OFF po-
sition.
WARNING
Batteries contain sulfuric acid which can cause severe

burns. Avoid contact with skin, eyes, or clothing. ANTI-
DOTES Recommended by Battery Manufacturers: EX-
TERNAL ANTIDOTE: flush with water. Flush eyes for at
least 15 minutes. INTERNAL ANTIDOTE: drink large
quantities of water. Do not induce vomiting. CALL A
PHYSICIAN IMMEDIATELY AND GET PROMPT ATTEN-
TION! Failure to do so could result in personal injury or
death. M-120-R4
WARNING
Batteries produce explosive gasses when being charged

or discharged. ALWAYS wear eye protection when using
booster batteries and/or starting generators. Batteries
can explode if a spark or flame comes near the battery
causing possible personal injury or death. M-106-R4

CAUTION
To prevent damage to the engine alternator, circuits

or ECM (later models), use care not to reverse the po-
larity to the machine's batteries. Immediate damage
to these components can result.
2. Connect the booster batteries or starting generator using the

following procedure to prevent a spark near the battery that
can cause an explosion.
a. Connect one jumper cable to the positive (+) terminal of the

booster battery. Connect opposite end of the same jumper ca-
ble to the positive (+) terminal of the battery on the machine.
b. Connect the other cable to the negative (-) terminal of the

booster battery. Connect the opposite end of this cable to a
good ground connection on the machine's frame, away from
the battery.
33059
3. Start the engine in the normal manner.
4. After the engine has been started, first disconnect the negative (-)
booster cable from the frame, then remove the positive (+) booster
cable. SMT-0088a)

CRANE WARM-UP PROCEDURE
(SMT-0184b-2
Above 40° F
When the crane has been shut down for an hour or more, allow the engine
to run at LOW RPM for about 5 minutes then switch to HIGH RPM.
NOTE: Automatic engine controls delay HIGH RPM operation until

minimum engine coolant temperature is reached.
Below 40° F
1. In very cold conditions, be sure that the temperature is not below the
pour point of the oil.
CAUTION
If the temperature of the hydraulic oil is below its pour point,

do not start the engine. Immediate pump damage may result.
OP-151
NOTE: The pour point temperature changes with the type of

hydraulic oil used. When operating during colder temperatures,
maintenance must provide this information to the operator.
2. Start the engine and run at LOW RPM for about 5 minutes then switch
to HIGH RPM.
NOTE: Engine speed will not increase until minimum engine coolant
temperature is reached.
3. After the engine is running at high RPM, operate the crane functions to
warm the oil in each circuit.
NOTE: A longer warming period is necessary during colder tempera-

tures.
© -2004 - MI-JACK Products, Inc. OP-5-25B.02 - 1

HOIST CIRCUIT WARM-UP
Operate the hoist “UP” and “DOWN” at 1/2 speed maintaining a dis-
tance of 2 feet from the end of travel in each direction.
IMPORTANT: While warming the circuits, do not operate over relief.
DRIVE CIRCUIT WARM-UP
Operate the crane approximately 200’ in both directions at 1/2 speed.

Continue operating for an additional 5-minute period. This will provide
the additional heat necessary to maintain minimum temperatures during
operation.
NOTE: Plugging in and using the hydraulic tank heaters and engine
block heater (if equipped), while the crane is shut down, will reduce the
amount of warm-up time required during colder temperatures.
SMT-0184b-2)
OP-5-25B.02 - 2 © - 2004 - MI-JACK Products, Inc.

STEERING
(SMT-0093-8
The crane is steered by turning the rear wheel yokes. The steer control
opens and closes a valve to provide hydraulic power to turn the yokes.
There is no mechanical linkage between the steer control and the steer-
ing yokes. Because of this , THE STEERING YOKES HAVE TO BE
CHECKED REGULARLY FOR ALIGNMENT. Checking the alignment is
covered under your daily checks.
Standard Steering -
During maximum turn, the inside rear wheel turns to the maximum angle.
The crane rotates around a common point as shown below. When
turning, the steer wheels are at different angles. The wheels are parallel
only during travel in a straight line.
TUR
NIN
G RA
DIU
S
PIVOTING WHEEL
FRONT
CAB
RIGHT
REAR
18171d.TIF
Turning Radius -
The turning radius of the crane is measured across the crane as shown in
the illustration. This measurement (A) is made from the outside of the
front wheel to the outside corner of the rear wheel. This is the minimum
turning radius. Additional distance must be added for clearance.
SMT-0093-8)
© -2004 - MI-JACK Products, Inc. OP-5-35G.01 - 1

DRIVING (TRAVELING)
(SMT-0091-11a
The Drive System uses two motors. Power output from the hydraulic
motors goes through roller chains and sprockets to the drive wheels.
Hydrostatic braking, through the drive motors, is used to stop the
machine. Brakes mounted at the drive motor act as a parking brake.
Always remember:
• Be sure all personnel are

clear of the crane before
moving it.
• Never allow anyone to ride

on the crane or its attach-
ments.
33039
WARNING
The only person required

on the crane when it is
operating is the Operator.
Never allow anyone to ride
on the crane or its attach-
ments. Personal injury or
death can result from the
rider falling, becoming en-
tangled in the crane's
mechanism, or being
crushed between moving
parts of the crane, or the
crane and other structures. 33037
OP-134-R2
• Before moving the TRAVELIFT, the hook blocks should be raised until the
hook block is nested around the top beam. This procedure will prevent
swaying of the load and provide maximum load stability while traveling.
NOTE: Although it is permissible to have the hook block fully raised, it is

recommended that the hook block be lowered slightly from the fully raised
position so that it is not in direct contact with the trolley.
© -2005 - MI-JACK Products, Inc. OP-5-40J.02 - 1

CAUTION
Do not travel with lifting slings, chains or straps attached to

trolleys. Hooks can catch on loads or items being straddled,
causing crane or material damage.
• When in the drive/gantry mode, no other functions should be oper-

ated. Your primary concern should be to safely steer and stop the
machine.
CAUTION
This crane is capable of multiple-function operation

while traveling. Extreme caution must be exercised by
the operator to ensure proper clearances at all times to
avoid collisions.
33120
OP-5-40J.02 - 2 © - 2005- MI-JACK Products, Inc.

33003
CAUTION
If the machine collides with an object, (however slight), is

impacted by another vehicle, or gets stuck in a chuck hole,
surface irregularity, or between tracks away from a cross-
ing, for example, the operator must immediately take the
machine out of service and notify the appropriate mainte-
nance personnel. Maintenance personnel must inspect
the machine for structural damage, prior to continuing
further operations. Failure to do so can result in serious
equipment damage. Maintenance personnel are to notify
the MI-JACK Products Regional Service Manager when
any MI-JACK machine is involved in an incident and incurs
damage. G-115b
WARNING
If ground persons are used, do not move the crane

without the proper signal from your groundcrew. They
must be in view at all times. Stop the crane if he/she
disappears from your view. Failure to do so could result
in personal injury or death. OP-112d

Drive/Gantry Forward or Reverse: DRIVE
DRIVE SELECTOR
PEDAL
1. Rotate the drive selector
counterclockwise to place it in
the forward position, or
clockwise to place it in the
reverse position.
2. Check for a clear path of travel

and get the OK from your
groundcrew (If used).
18935.TIF
3. Depress the drive pedal to
move the crane in the se-
lected direction. The greater
the pedal is depressed, the
faster the crane will travel.
NOTE: The travel alarms will

sound when the drive control-
ler is moved.
33039
IMPORTANT: The operator must always look in the direction of travel

and if utilized, follow the groundcrew's signals.
WARNING
Do not drive the crane without first sounding the horn and
observing where any ground personnel may be located.
Serious injury or death can result if this procedure is not
followed.
OP-143-R2
4. Move the DRIVE PEDAL gradually and smoothly to travel the desired
speed.
IMPORTANT: The operator must continue to check clearances while

driving.

5. To slow or stop the crane:
a. To slow the crane, release the drive/gantry controller an appropriate

amount.
NOTE: The more the controller is released, the more the crane will slow.
b. To stop the crane release the drive/gantry controller completely.
NOTE: When the drive/gantry controller is released the drive/gantry

motors will dynamically stop the crane.
NOTE: Once the crane has stopped, the parking brakes will apply
automatically and the travel alarm will stop sounding.
IMPORTANT: The parking brakes are mounted at the drive motors and
are for holding the crane; not stopping it.
NOTE: The park brakes will release when the drive/gantry controller is
moved.
NOTE: Do not attempt to change direction of travel while the crane is

still moving. Allow the crane to stop its motion before changing
direction. Attempting to change direction of travel while driving will
cause the drive function to be disabled. To restore the drive function
the the machine must be brought to a complete stop, the drive pedal
released, and the drive selector rotated to the desired direction of
travel.
VARIABLE STOPPING DIS-

TANCE REQUIRED TO AVOID
COLLISION
33122
WARNING
The machine's inertial force resulting from its speed and

weight influences how quickly the machine can be stopped
just like any other vehicle. Because of the machine's gross
weight, it cannot be stopped instantly. A variable distance
is required to stop the machine, depending on load and
speed. Be sure to allow adequate stopping distance when
driving. Failure to do so could result in machine damage,
personal injury or death. OP-138d

WARNING
In the event the crane becomes stalled by an obstacle,

switch the drive selector to neutral, and turn off the igni-
tion. Block the wheels if the crane is on an incline. This
will allow the obstacle to be removed without moving the
crane. Do not attempt to remove the obstruction while the
crane is driving against it. Otherwise, the crane may move
resulting in possible serious injury or death. OP-156b-1
SMT-0091-11a)
33121

TRAVERSING
(SMT-0120b-3
The traverse system controls the movement of the trolleys across the top
beams by roller chains and is controlled by the traverse controllers.
To move the trolleys:
1. Pull the traverse controller back to move the trolleys toward the
operator. Pushing the controller away will move the trolleys away
from the operator. The front and rear trolleys act independently. The
controllers can be actuated together or separately.
REAR
TRAV ERSE
CONTROLLER
FRONT
TRAV ERSE
CONTROLLER
16066.TIF
© -2006 - MI-JACK Products, Inc. OP-5-50N.01 - 1

2. Accelerate the trolleys smoothly by gradually moving the controllers.
NOTE: Trolley speed is proportional to the amount of deflection of the

controller handle.
To stop the trolleys:
Gradually return the Traverse Controllers to neutral.
IMPORTANT: Gradually decrease the traverse speed before completely

stopping. Never allow the controllers to spring back; always hand position
the controllers back to neutral. DO NOT run the trolleys at full speed against
the stops.
OP-5-50N.01 - 2 © - 2006 - MI-JACK Products, Inc.

OP-5-55I.01.fm Page 1 Monday, March 6, 2006 10:35 AM
HOISTING
(SMT-0119b-8
The Hoist System raises and lowers the hook blocks through a wire
rope and sheave system. The wire rope drum is powered by a hydrau-
lic motor through an automatic brake that holds the load in position af-
ter the hoist has stopped.
Hoisting is accomplished by moving one or both of the hoist control-

lers. The controllers activate the front and rear hoist actuators inde-
pendently. Movement of the hoist controllers are proportional; the
farther the handle is moved, the faster the hoist will operate.
IMPORTANT: Never change direction of hoist movement until the
hoist has completely stopped.
NOTE: The holding brake for the hoist is hydraulically released. The
engine must be running and hydraulic pressure must be available to
the hoist motor to release the hoist brake before the load can be low-
ered.
FRONT REAR
HOIST HOIST
CONTROLLER CONTROLLER
© - 2004 - MI-JACK Products OP-5-55I.01-1

To hoist up or down:
• Push the hoist controller forward toward the "DOWN" position to

hoist down and pull the hoist controller back toward the "UP" posi-
tion to hoist up. Movement of the controller is proportional; the fur-
ther they move from the center (neutral) position, the faster the
crane will hoist. The front and rear hoists act independently. The
controllers can be actuated together or separately.
IMPORTANT: The hoist should not be run at full speed to the fully
lowered or raised positions.
IMPORTANT: Hoist down only far enough to attach the load to

the hook blocks. Do not allow the hoist wire ropes to become
slack. Doing so can cause damage to the wire ropes or other
hoist system components.
To stop the hoist:
• Return the Hoist Controller to neutral.
NOTE: Do not remove your hand from the controller and allow it to
spring back to neutral. Damage to the controller can occur.
IMPORTANT: If either hook continues to hoist or "drift" after the

controller has been released, immediately notify appropriate mainte-
nance or service personnel.
IMPORTANT: The hook blocks should be raised until the hook block
is nested around the top beam. This procedure will prevent swaying
of the load and provide maximum load stability while traveling.
NOTE: Although it is permissible to have the hook block fully raised,

it is recommended that the hook block be lowered slightly from the
fully raised position so that it is not in direct contact with the trolley.
SMT-0119b-8)

WARNING
Sudden hoisting movements or reversals can damage the

crane, including the breakage of hoist system compo-
nents, which can result in serious personnel injury or
death from falling loads. OP 141-R2
33056

LOAD HANDLING - WITH HOOKS OR STRONGBACK BEAM
(SMT-0168-3a
The following suggested procedures are for handling loads directly from the
hook blocks or strongback beam.
CAUTION
Prior to lifting any load, the gross weight of the load must be
known. YOU must not attempt to lift any load that may exceed
the rated capacity of the crane. Doing so could result in failure
of crane components and serious damage to equipment and
the load.
CAUTION
Although the front and rear hoists can be operated indepen-

dently or simultaneously, to help prevent damage to equip-
ment the maximum allowable displacement of a strongback
from level is 10°.
STRONGBACK
18423b.TIF
LEVEL
10°
CK
NGBA
STRO
18423a.TIF
MAXIMUM TILT

CAUTION
Skewing must be held to a minimum when the hook blocks are

in close proximity to the top beam. In this position, excessive
skewing, greater than 5°, can cause damage to the equipment.
5°
1. Drive the crane to a position over the load to allow a straight lift.
WARNING
The operator and the groundcrew, if utilized, must be in

constant communication with each other at all times.
Review the communication system to be used before
starting. Both persons must know the proper hand
signals for each movement of the crane or load. A
failure in communications can cause an accident result-
ing in serious personal injury or death. OP-113-R3
OP-5-70G.03 - 2 © - 2004 - MI-JACK Products, Inc.

2. Traverse the hook blocks or beam over the load.
WARNING
Make sure the hoist is directly over the load before lifting. Side
pull on the hoist can cause damage to the crane and/or
possible personal injury or death. OP-130-R4
88-18-01A-0

3. Lower [hoist down] the hook blocks, or beam, sufficiently for hooking to
the load as directed by your groundcrew.
WARNING
DO NOT attach two separate loads on one hoist, even if the

total load is within the lifting capacity of the hoist. The loads
can slide out of position resulting in machine damage,
personal injury or death. OP-127-R4
88-18-01B-0
WARNING
Make sure that the load is safely connected to the hook

blocks or spreader, and that all personnel are away from
the immediate area before hoisting, driving, or traversing
the load. Sound the horn and wait for the area to be
cleared before moving the load. Failure to do any of the
preceding could result in personal injury or death. OP-120-R3

4. After the load is attached, raise [hoist up] the load when safe to do so.
IMPORTANT: Before moving the TRAVELIFT with a load attached, the hook
blocks should be raised until the hook block guides straddle the trolley, but
the hook block must not be tight against the trolley. This procedure will
prevent swaying of the load and provide maximum load and crane stability
while traveling.
WARNING
Excessive sway of the load may cause the crane to tip over
if the crane is stopped quickly. To avoid this, the load should
always be fully hoisted when traveling and the crane should
be stopped smoothly. Failure to do so could result in personal
injury or death. OP-163-R2
18421
WARNING
Use extreme care when operating with a load on one hook

only. Sudden stops from braking, obstacles, etc., can cause
load swing and a possible tipping condition of the crane
resulting in machine damage, personal injury or death.
OP-126-R2

5. If the load is to be traversed, be sure that the area is clear, and the load
is free to move. Traverse gradually as your groundcrew gives the signal.
WARNING
NEVER pass a load over the head of anyone, including drivers

in truck cabs. Sound the warning horn and wait for the
person to clear area before moving the load. Failure to do
so could result in personal injury or death. OP-140-R3
18420

6. If the load is to be relocated, check that your path is clear and drive to
the new location. Periodically check the position of the load when
traveling.
6 FT.
MIN.
90-33-010-0

7. Release the drive pedal.
WARNING
The machine's inertial force resulting from its speed and weight
influences how quickly the machine can be stopped just like any
other vehicle. Because of the machine's gross weight, it cannot be
stopped instantly. A variable distance is required to stop the
machine, depending on load and speed. Be sure to allow
adequate stopping distance when driving. Failure to do so could
result in machine damage, personal injury or death. OP-138d
8. When safe to do so, slowly lower [hoist down] the load. Traverse the
load as necessary to correctly spot it.
WARNING
Be exact in load placement. Make sure the load will not tilt, fall,
or slide out of position when released. Personal injury or
equipment damage can result from unstable placement of loads
can result in personal injury or death. OP-122R1
SMT-0168-3a)
90-33-063-0

SHUTDOWN PROCEDURES
(SMT-0100-8
1. Remove all loads, fully raise the hooks.
WARNING
NEVER leave the crane with a load suspended. It could

inadvertently lower, possibly causing serious injury or death.
OP-123
2. Move the crane to its designated parking area.
WARNING
Do not move the crane onto a surface or area that has not
been approved for the crane. The crane is heavy and could
possibly break through an insufficient surface, causing
damage to the crane or injury to personnel. OP-109
WARNING
Never park the crane on an incline. Always park the crane on

level ground. Otherwise, the crane could possibly roll
resulting in possible injury to personnel or damage to the
crane. OP-157
3. Turn the wheel yokes to their straight ahead position, if they are not
already.
4. Make sure all controls are in the NEUTRAL position and all electrical
accessories and lights are OFF.
© -2002 - MI-JACK Products, Inc. OP-5-75B.01 - 1

5. Select LOW RPM and allow the engine to idle for 3-5 minutes.
CAUTION
The engine must be idled 3 to 5 minutes before shutting

down to allow the engine to cool slowly and evenly. Other-
wise, severe damage to the engine or related components
can result. OP-124
6. Turn the Ignition switch to the OFF position.
7. Remove all personal articles and materials from the cab.
8. Fuel the crane to prevent condensation from accumulating inside the

fuel tank.
WARNING
The person fueling the crane must be trained in the proce-

dure. Otherwise, spillage can result, possibly causing skin
irritation and/or a fire hazard. OP-201
9. Connect the ground power, if needed. (If equipped).
DANGER
Ground power is high voltage (220 VAC). To avoid electrical

hazards, such as electrocution, always follow accepted
procedures for handling high voltage equipment. OP-203a
10. Visually inspect the crane again for any maintenance or operational
problems that need to be reported to maintenance personnel.
SMT-0100-8)
OP-5-75B.01 - 2 © - 2002 - MI-JACK Products, Inc.

TOWING
(SMT-0101-1
MI-JACK Products does not recommend towing this crane.
WARNING
Towing any crane without taking the proper prerequisite steps

could result in damage to equipment and possible personal
injury. G-118-R1
If it is absolutely essential that the crane must be towed, contact MI-

JACK Technical Services for assistance.
SMT-0101-1)
© -2002 - MI-JACK Products, Inc. OP-5-80A - 1

SECTION 6
OPTIONAL EQUIPMENT

NOTES

AIR CONDITIONING
(SMT-0102
The controls for the air conditioner are on top of the unit. Adjustable louvers
and a deflector permit the operator to control the movement of cooling air
through the cab.
Selector Switch - The selector switch has 6 positions and determines the
mode of operation the air conditioner will be in: OFF, LO HEAT, LO FAN,
HI FAN, LO COOL, & HI COOl. These positions select the air conditioner
fan speed.
Temperature Control (thermostat) - In the cooling mode, the thermostat

regulates the ON and OFF temperature setting at which the compressor will
operate. Switching to MAX COOL, bypasses the thermostatic control and
locks the compressor in the cooling mode for continuous cooling.
In the HEAT mode the thermostat regulates the ON and OFF temperature
setting at which the heating element will operate. Constant heating
operation from bypassing the thermostatic control is not available.
SMT-0102)
AIR CONDITIONER CONTROLS 18172
© • 2004 • MI-JACK Products, Inc. OP-6-3A - 1

"C" SPREADER OPTION
MODELS:
TRAVELIFT MACHINES WITH C SPREADER PACKAGE
SUBJECT:
"C" SPREADER OPERATING CONTROLS, LOAD HANDLING
PROCEDURES and PRECAUTIONS
This module supplements this crane operator's manual in regard to the

operation of the optional "C" Spreader package.
"C" SPREADER ORIENTATION:
The "C" spreader is hydraulically operated and contains four twistlocks for
top picking containers. The twistlocks are mounted on spreader beams which
are extended and retracted by two hydraulic cylinders. When fully extended
the spreader is positioned to pick containers equipped with standard 40' pick
points. Fully retracted, the spreader is positioned to pick 20' containers.
This spreader can be equipped with the WTP (Wide Twistlock Position)
option. This option allows the width spacing of the twistlocks to be changed
hydraulically which allows lifting containers with standard 8'-0" spacing and
wide containers with 8'-6" spacing.
SPREADER BEAMS
10030
TWISTLOCK
© • 2006 • MI-JACK Products, Inc. OP-6-25C - 1

OPERATOR CONTROLS
1 2 3 4 5
16096.TIF
6 7
8
10
16094.TIF
OP-6-25C - 2 © • 2006 • MI-JACK Products, Inc.

1. 20' INDICATOR LIGHT
This light illuminates when the spreader is in the 20' position.
2. 40' INDICATOR LIGHT
This light illuminates when the spreader is in the 40' position.
3. LATCH INDICATOR LIGHT
When the twistlocks are latched the LATCHED indicator will illuminate.
Hoisting is permitted only after the LATCHED light is illuminated.
NOTE: The twistlock control will not function unless the position light
is illuminated.
4. POSITION INDICATOR LIGHT
This light illuminates when the position probes on all four twistlocks are
actuated by setting the spreader onto the container corner blocks.
Latching and unlatching of the twistlocks can only occur after this light
is illuminated.
NOTE: The hoist "down" function is locked out when this light is
illuminated.
5. UNLATCH INDICATOR LIGHT
The UNLATCH (unlocked) indicator light will illuminate when the

twistlocks are unlatched.
NOTE: The twistlock control will not function unless the position light
is illuminated.
6. AUTOMATIC EXTEND/RETRACT CONTROL
The spreader automatic extend/retract control is used to position

the twistlocks by extending or retracting the spreader beams.
Pressing and releasing the top of the control automatically extends
the spreader beams to the 40' position; pressing and releasing the
bottom of the control automatically retracts the spreader beams to
the 20' position.
IMPORTANT: Pressing either side of the MANUAL EXTEND/

RETRACT control will stop the automatic movement of the spreader
beam.

7. MANUAL EXTEND/RETRACT CONTROL
The spreader extend/retract control is used to position the

twistlocks by extending or retracting the spreader beams. Pressing
and holding the top of the control extends the spreader beams until
the control is released; pressing and holding the bottom of the
control retracts the spreader beams until the control is released.
8. TWISTLOCK LATCH/UNLATCH
The twistlock latch/unlatch control is used to latch or unlatch the

twistlocks. Pressing the top of the control will cause the twistlocks
to latch; pressing the bottom of the control will cause the twistlocks
to unlatch. "LATCHED" and "UNLATCHED" lights mounted on the
spreader and/or the operator console will illuminate appropriately
when the twistlocks move to either the latched or unlatched posi-
tion. The "LATCHED" light must be ON before attempting to lift a
load, and the "UNLATCHED" light must be ON before attempting to
disconnect the spreader from the load.
NOTE: The twistlocks will not latch or unlatch unless the "POSITION"
light mounted on the spreader and/or the operator console is illuminated.
The "POSITION" light only illuminates when the position probes at all four
twistlocks are actuated by positioning the spreader onto the container
corner blocks. Both front and rear Hoist "Down" functions are locked
out when this light is illuminated.
9. SPREADER START CONTROL
Pressing the green START control energizes the spreader motor/pump.
NOTE: The spreader motor/pump must be running before any spreader

function will operate.
NOTE: The START control will illuminate whenever the spreader motor/
pump is energized.
10. SPREADER STOP CONTROL
Pressing the red STOP control will de-energize the motor/pump,

stopping all spreader functions.
NOTE: The STOP control will illuminate whenever the machine key
switch is in the ON position.

GENERAL OPERATING PROCEDURES
(SMT-0169a-1
CAUTION
Although the front and rear hoists can be operated indepen-

dently or simultaneously, to help prevent damage to equip-
ment, the maximum allowable displacement of the spreader
from level is 10º. OP-165-R1
Spreader Level
10o
93-18-423-0
Spreader Maximum Tilt Limit

CAUTION

SMT-0169a-1)
5°
91-18-213-0
CAUTION


LOAD HANDLING
(SMT-0094-10
WARNING
Be sure that you know the location of all groundcrew personnel

in the crane's operating vicinity. Failure to do so could result
in personal injury or death. OP-200a
The basic spreader functions are:
- Extend and retract the sliding carriage.

- Lock and unlock the twistlocks.
- Standard and Wide Twistlock Position control - Optional
• Start Up
1. If equipped with a self contained motor/pump, press the START

control to energize the system.
NOTE: Spreader functions will not operate unless the START control
is pressed.
NOTE: Press the red STOP control when the spreader functions are
not needed.
• Container Handling
1. If equipped with WTP, select either the standard or wide twistlock

position.
NOTE: Refer to the "OPERATOR'S CONTROLS" section for WTP

controller operation if equipped with WTP.
2. Extend or retract the spreader using the EXTEND and RETRACT

function until the correct twistlock spacing is achieved.
NOTE: The spreader should be approximately level when extending

or retracting.
3. Using both hoist and traverse controllers, center the spreader over the
container. Lower the spreader until the twistlocks are approximately
12 inches above the container. (See illustration on the following page)

4. Line up the twistlocks above the container and slowly lower the
spreader. When approximately 3 inches above the container, lower
only the front or rear of the spreader until the twistlocks are inserted
into the corner blocks. (See illustration below)
WARNING
If the crane has to be moved to align the spreader, check for

clearance before moving the crane. Failure to do so could
result in equipment damage and/or personal injury or
death. OP-173c
5. After the twistlocks on one end of the spreader are partially inserted
into the corner blocks, lower the other end while continuing to lower
the first end. It may be necessary to drive, trolley, hoist, or side
shift, if equipped, to properly insert the twistlocks into the corner
blocks.
6. Lower the spreader completely onto the container.
IMPORTANT: The front and rear hoists operate independently.

During hoist down, when the front position probes, on the spreader,
contact the container, the front hoist "DOWN" function is locked out.
Likewise, when the rear position probes, on the spreader, contact the
container, the rear hoist "DOWN" function is locked out.
12 inches
3 inches
33058

7. Once all four corners of the spreader are resting on the container
(indicated by the POSITION Light coming on) use the LATCH function
to latch all four twistlocks.
8. After all four twistlocks are latched (indicated by the LATCHED Light
coming on) the operator may then lift the container.
NOTE: The container must be hoisted fully up (but not two blocked)
prior to traveling.
WARNING
NEVER attempt to lift a container unless ALL 4 twistlocks are

latched into the container. Doing so can result in dropped
containers causing damage to the lifting equipment, the
container and/or personal injury or death. OP-146-R4
WARNING
NEVER pass a load over the head of anyone, including

drivers in truck cabs. Sound the warning horn and wait for
the person to clear area before moving the load. Failure to
do so could result in personal injury or death. OP-140-R3
9. After the container has been moved, lowered to the ground, or onto a
chassis, and the POSITION light is illuminated, use the UNLATCH
control to unlatch the twistlocks from the container. The twistlocks
are unlatched when the UNLATCHED light is illuminated.
WARNING
Hoist system electrical interlocks have been installed on

this machine to help protect against personal injury and/or
damage to equipment. Under no circumstances should any
attempt be made to disconnect or in any way render this
interlock inoperative. If a malfunction of the hoist interlock
is discovered to exist, DO NOT operate the machine.
Immediately notify appropriate maintenance personnel.
Failure to do so could result in equipment damage, per-
sonal injury or death. G-120a

CAUTION
Do not raise the spreader away from the container until

the UNLATCHED indicator light is illuminated. A twistlock
may be jammed and possible container damage could
result during hoisting in this situation. OP-158
WARNING
Do not unlatch a container until YOU, the operator, have

determined that it is safe to do so. Unlatching from a
container that is not positioned securely could cause
shifting or falling resulting in damage to the lifting
equipment, the container and/or personal injury or
death. OP-147-R3
IMPORTANT: Operators must be aware of problems which can

arise, specifically, when operating in double-stack situations, loaded
or unloaded. If proper alignment is not made prior to hoisting down,
the spreader frame, or container, may come to rest on the adjacent
car or container. Continued lowering of the hoist will create slack in
the hoist ropes. If this condition occurs, stop hoisting down immedi-
ately, and slowly hoist up until all slack is removed from the hoist
ropes and stop. Check that the ropes are properly seated in the
sheaves, then hoist the spreader up to clear the car or container.
Re-level the load, and properly align the spreader and/or the con-
tainer. Attempting to realign the spreader with slack ropes can
cause the ropes to become unseated from the sheaves and the
spreader/container to drop violently, resulting in potentially serious
damage.
WARNING
Avoid all situations that could allow the load or spreader

to drop suddenly. If the spreader or container becomes
stuck, or hangs on something, it should be hoisted back
up and proper alignment accomplished by driving, tra-
versing or side shifting, if equipped, as required. Failure
to attain proper alignment prior to hoisting down could
result in slack hoist ropes, resulting in a sudden shift or
drop of the load, causing severe damage to equipment
and or personal injury or death! OP-175a-1

WARNING
The operator and the groundcrew, if utilized, must be in

constant communication with each other at all times.
Review the communication system to be used before
starting. Both persons must know the proper hand signals
for each movement of the crane or load. A failure in
communications can cause an accident resulting in seri-
ous personal injury or death. OP-113-R3
33003
WARNING
Be exact in load placement. Make sure the load will not tilt,
fall, or slide out of position when released. Equipment
damage, personal injury or death can result from unstable
placement of loads. OP-122R1
SMT-0094-10)
33063

Operator'S Manual: Hazel Crest, Illinois 60429 - 708/596-5200 - FAX: 708/596-9076

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Operator'S Manual: Hazel Crest, Illinois 60429 - 708/596-5200 - FAX: 708/596-9076

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OPERATOR'S

TRAVELIFT ® CRANE MJ50

SAFETY DECLARATION TO THE OPERATOR

In some instances groundcrew may be used. However, all operating

Any references in this manual to the use of groundcrew is not intended

Wheel guards and optional drive shut-down systems are intended to

Hazel Crest, Illinois 60429 • 708/596-5200 • FAX: 708/596-9076

© Copyright • 2006 • MI-JACK Products FEBRUARY 2006

Employees should be aware of possible dangers in operating or working

Working in the area of industrial equipment is dangerous. Certain

INTRODUCTION ........................................................................... OP-1-0A

GENERAL SAFETY ...................................................................... OP-2-0A

GROUNDCREW SAFETY GUIDELINES

GROUNDCREW SAFETY GUIDELINES ...................................... OP-3-0A

OPERATOR’S CONTROLS........................................................... OP-4-0A

OPERATING PROCEDURES ....................................................... OP-5-0A

PLANNED MAINTENANCE .......................................................... OP-0-6A

© - 2004 - MI-JACK Products OP-1-0A-1

© - 2004 - MI-JACK Products OP-1-0A-2

This machine must be operated by trained personnel only.

You are about to operate the finest MACHINE in the industry.

Most importantly, operate your machine in a safe and efficient manner. Be

The mark of an experienced operator is safe, efficient, well-thought-out

Operator instruction is available for present or new operators by contacting

© - 2002 - MI-JACK Products OP-1-1A.01-1

MI-JACK shall have no liability with respect to:

• repairs improperly performed.

As part of MI-JACK Products' on-going program to improve its products

© - 2004 - MI-JACK Products OP-1-2A.02-1

A variable distance is required to stop the crane, depending on the

Although it may be possible to stop an automobile traveling at 5 MPH in

Be sure to allow ample stopping distance when driving to avoid col-

150 140 130 120 110 100 90 80 70 60 50 40 30 20 10

Working in the area of industrial equipment is dangerous. Cer-

© - 2004 - MI-JACK Products OP-1-2A.02-2

FORWARD Left Side View

1. Drive Wheel 7. Operator's Cab and Controls

© - 2004 - MI-JACK Products OP-1-3U-1

The crane is hydraulically powered through hydraulic piston pumps which

© - 2004 - MI-JACK Products OP-1-3U-2

© - 2004 - MI-JACK Products OP-2-0A-1

© - 2004 - MI-JACK Products OP-2-0A-2

READ THIS MANUAL COMPLETELY AND MAKE SURE YOU UNDER-

It is recommended that you make copies of the safety guidelines in this

USING COMMON SENSE

© - 2002 - MI-JACK Products, Inc. OP-2-1A - 1

“NOTE” is the term used whenever information requires

“IMPORTANT” is the term used whenever information

“CAUTION” is the term used whenever there is potential for

“WARNING” is the term used whenever there is a potential

“DANGER” is the term used whenever there is an immedi-

This safety alert symbol indicates important safety mes-

© - 2002 - MI-JACK Products, Inc. OP-2-2A - 1

Working in the area of industrial equipment is dangerous. Certain

In addition, MI-JACK recommends that operators and operator trainees must

© - 2002 - MI-JACK Products, Inc. OP-2-3A.01 - 1

Electrical, mechanical, and hydraulic safety devices have been

© - 2002 - MI-JACK Products, Inc. OP-2-4A.02 - 1

IMPORTANT: To ensure the continued safe operating conditions of the

The use of two way radios or other electronic devices may

MI-JACK Products does not recommend towing this machine except in

If it is absolutely essential that the machine must be towed, contact

Towing any machine without taking the proper prerequisite