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534D-9 534D-10

1. MACHINE SERIAL NUMBER PLATE Figure 12 5 Description of items on a Capacity Chart Capacity Chart Part No shown on reverse side This Capacity Chart may be used with this model ONLY DEDUCT 300 LBS FROM ALL CAPACITIES WHEN MACHINE IS EQUIPPED WITH WINCH Boom Extension Numbers y 179 4000 LBS 5000 LBS a Boom Angle NOTE This is a sample Capacity Chart ONLY Do not use this chart use the one located in your cab Regions indicate the maximum weight that may be lifted USE WITH 9108 5058 48 SLOPE PILER These numbers 9130 5016 66 SLOPE PILER must match the Part No stamped on the attachment ID Plate Form No 20219 534D 9 534D 10 Owner Operator Manual 13 0 ATTACHMENTS Approved Attachments Although the carriage fork combination is most frequently used several other GRADALL approved attachments are available for use with your material handler Contact your GRADALL Material Handler Distributor for information on approved attachments designed to solve special material handling problems The serial number plate lists attachments approved for use with your handler However there may be additional approved attachments available Contact your GRADALL Material Handler Distributor for further information Non Approved Attachments Do not use non approved attachments for the following reasons GRADALL cannot
2. Semi Annual or 1000 Hour Lubrication amp Maintenance Include all previous periodic services 3 Front Axle Breather clean or replace 5 6 Planetary and Differential Drain Plugs drain fill to level wait 5 minutes and fill to level again item 2 is level plug 12 Hydraulic Reservoir Breather Cap clean or replace 46 Rear Hub Drain Plug drain and refill item 47 is fill plug HF HF Annual or 1500 Hour Lubrication amp Maintenance include all previous periodic services 10 Hydraulic Return Filter replace filter element 11 Hydraulic Suction Filter replace filter element 12 Hydraulic System unless fluid is analyzed quarterly to determine degree of contamination reservoir must be drained and refilled on an annual basis 14 Hydraulic Reservoir Screen remove clean and install when hydraulic oil is drained 32 Engine Cooling System drain flush and refill on basis of period suggested by anti freeze manufacturer and add Liquid Coolant Additive HF if equipped with Deere engine AF CC DETAILED SERVICE INSTRUCTIONS ARE CONTAINED IN THE GRADALL SERVICE MANUAL FOR YOUR PARTICULAR MATERIAL HANDLER Form No 20219 534D 9 534D 10 Owner Operator Manual 17 2 RECOMMENDED LUBRICANTS amp CAPACITIES APPLICATION SYMBOL araoe SPECIFICATION CAPACITY Boom Cable Adj HM Threads extreme pres moly lube All Year P N 1440 3323 Boom Slide Bearing Paths extreme n moly lube
3. WARNING LEAD ACID BATTERIES PRODUCE FLAMABLE AND XPLOSIVE GASSES WHEN CHECKING TESTING USING BOOSTER BATTERY OR CHARGING BATTERIES DO NOT USE SMOKING MATERIALS NEAR BATTERIES KEEP FLAMES AND SPARKS AWAY FROM BATTERIES WEAR SAFETY GLASSES ASSURE BATTERY IS NOT FROZEN AND ELECTROLYTE IS AT PROPER LEVEL IN EACH CELL FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DAMAGE TO THE ELECTRICAL SYSTEM Located beside battery P N 9114 3285 DANGER AVOID HIGH VOLTAGE LINES IT IS UNLAWFUL TO PLACE ANY PART OF THIS MACHINE OR LOAD WITHIN 10 FEET OF HIGH VOLTAGE LINES UP TO 50 000 VOLTS DEATH OR INJURY MAY RESULT FROM CONTACTING ELECTRIC LINES Located beside battery P N 9114 3284 WARNING DIESEL FUEL IS FLAMMABLE EXTINGUISH ALL OPEN FLAME AND SMOKING MATERIALS WHEN REFUELING INJURY OR DEATH COULD RESULT FROM FIRE 9114 3286 Located on mud guard P N 8060 3022 Located on fuel tank P N 9114 3286 A WARNING PINCH POINT KEEP OUT REACHING INTO BOOM HOLES AND OTHER PINCH POINTS CAN CAUSE SERIOUS INJURY OR DEATH 8060 3037 A Located on boom P N 8060 3037 2 5 OUTSIDE THE CAB GRADALL HANDLER SERVICE INTERVALS SERVICE INSTRUCTIONS DALY WEEKLY EVERY
4. dL GRADALL OWNER OPERATOR MANUAL GRADALL 534D 9 534D 10 9134 4052 January 11 2007 534D 9 Starting Serial No 0544001 thru 0744407 amp 0160000112 thru 0160003965 534D 10 Starting Serial No 0366001 thru 0366533 amp 0160000125 thru 0160003965 Form 20219 Original Issue 6 03 CORPORATE OFFICE GRADALL DIVISION JLG INDUSTRIES INC JLG INDUSTRIES INC 1 JLG DRIVE 406 Mill Avenue S W McConnellsburg PA New Philadelphia OH 17233 9533 44663 USA USA Telephone 717 485 5161 Telephone 330 339 2211 Fax 717 485 6417 Fax 330 339 8458 534D 9 534D 10 MATERIAL HANDLER OWNER OPERATOR MANUAL COVERING OPERATION amp PERIODIC MAINTENANCE r e I n g C3 IMPORTANT Read and understand this Manual and the Gradall Material Handler Safety Manual before starting operating or performing maintenance procedures on this machine materi KEEP OPERATOR AND SAFETY MANUALS IN CAB A Company COVERS MATERIAL HANDLERS 534D 9 amp 534D 10 STARTING SERIAL NUMBERS 534D 9 0544001 thru 0744407 and Form No 20219 0160000112 thru 0160003965 Part No 9134 4052 534D 10 0366001 thru 0366533 and Revised 01 11 07 0160000125 thru 0160003965 IMPORTANT SAFETY NOTICE Safe operation depends on reliable equipment and proper operating procedures Performing the checks and services described in this Manual will help keep your GRADALL Material Handler in reliable condition Following recommend
5. mee Year 2 1440 4595 Coolant Conditioner CC supplemental All Year 0 5 qts 0 48L Deere Only coolant additive Engine Cooling System Cummins AF anti freeze All Year V2 amp V2 Permanent 24 qts Deere AF anti freeze All Year Vo amp V2 Permanent 24 8 qts Engine Crankcase Cummins EO engine oil All Year 15W 40 CD MIL L 2104D 12 qts Deere EO engine oil All Year 15W 40 CD MIL L 2104D 14 5 qts Front Axle Meritor HF hydraulic fluid All Year HUM 5 28 gal Carraro HF hydraulic fluid All Year id sd 4 91 gal 18 6L Fuel Tank DF diesel fuel All Year o o oo 40 gal 151 6L Grease Fittings HM extreme pres moly lube All Year NLGI 2 1440 4595 Hydraulic System HF hydraulic fluid All Year 47 gal 177 9 L Capacities are approximate check level to be sure Fill to level using Mobilfluid 424 GRADALL P N 1440 4535 Fill to level using Mobilfluid 424 OR Citgo Tractor Hydraulic Fluid product code 33310 N SR r TORQUE CHART Check torque using accurate torque wrench to apply maximum torque value shown DO NOT EXCEED MAXIMUM TORQUE Excess maximum torque may cause fastener to fail TORQUE lubricated ITEM FREQUENCY THREAD SIZE Lm LB us wu MART GRADE Boom Slide Bearings front 5 Weeks 250 hrs 3 8 24 5 5 Weeks 250 hrs 1 2 20 5 Boom Slide Bearings rear If front bearings have 3 8 24 5 worked loose 1 2 20 _ e Boom Extend Cable rear Adjusting Nut 5 Weeks
6. 11 USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM FOR LIFTING PERSONNEL NO RIDERS ON MACHINE FORKS LOAD OR OTHER LIFTING ATTACHMENTS AT ANY TIME DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL HANDLER PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN THE CAB DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM 12 KEEP OTHERS AWAY FROM MACHINE WHILE OPERATING DO NOT STAND UNDER BOOM OR LOAD 13 USE EXTREME CARE WHEN HANDLING LONG HIGH OR WIDE LOADS DO NOT HANDLE UNSTABLE OR LOOSELY STACKED LOADS 14 FORKS TO BE CENTERED UNDER LOAD AND SPACED APART AS FAR AS POSSIBLE 15 BEFORE ADJUSTING OR SERVICING PLACE FORWARD REVERSE LEVER IN NEUTRAL REST BOOM ON GROUND OR SUPPORT SET PARKING BRAKE SHUT OFF ENGINE AND CHOCK WHEELS 16 BEFORE LEAVING MACHINE UNATTENDED PLACE FORWARD REVERSE LEVER IN NEUTRAL LOWER BOOM SET PARKING BRAKE AND SHUT OFF ENGINE CHOCK WHEELS IF MACHINE MUST PARK ON AN INCLINE 17 LEVEL MACHINE BEFORE LIFTING ANY LOAD ABOVE 4 FEET IF EQUIPPED WITH FRAME LEVELING 18 OPERATOR PROTECTION SUCH AS HARD HATS SAFETY GLASSES AND OR HEARING PROTECTION SHOULD BE WORN WHEN JOB CONDITIONS WARRANT ALWAYS USE SEAT BELT 19 IMPROPER USE OF MACHINE COULD RESULT IN MACHINE TIPPING OVER IF MACHINE STARTS TO TIP OVER DO NOT LEAVE OPERATORS SEAT LEAN AWAY FROM TIP amp BRACE YOURSELF 20 KEEP MIRROR S CLEAN AND PROPERLY ADJUSTED OBJECTS IN MIRROR ARE CLOSER
7. ANNUALLY ype OR FOR 534D 9 534D 10 sors sovins 9505 soomes tooo soos EQUIVALENT DIESEL ENGINE A WARNING j DESELFUELE2 ATTACHMENT MUST BE SECURED TO MACHINE MOBIL424 CHECK TO ASSURE QUICK SWITCH PLUNGER E PIN IS FULLY ENGAGED AND LOCKED AFTER ATTACHMENT CHANGE IF PLUNGER PIN IS NOT FULLY ENGAGED MOBIL 424 AND LOCKED ATTACHMENT MAY FALL OFF CAUSING SERIOUS INJURY OR DEATH MOBIL 424 9114 3290 OIL 12 QT DIESEL FUEL 40 G ICHANGE BATTERY amp TERMINALS CHECK RADIATOR 3 GAL WATER SGALANTHFREEZE MO TIRES 13 00x24 12 PLY 65 PSI TIRES 14 00x24 12 PLY 65 PSI TIRES RADIAL 7OPSI CYLINDER FITTINGS EACH END REAR AXLE 12 FITTINGS FRONT AXLE PIVOT 2 FITTIN BEARINGS PADS FRONT BOTTOM BEARII BOOM PIVOT 2 FITTINGS HEAD PIN 2 FITTINGS BOOM SHEAVES 3 FITTINGS QUICK SWITCH 1 FITTING i sem RETRACT amp EXTEND CABLE 4 CHECK E SEE OPERATOR amp MAINTENANCE MANUAL ETHYLENE GLYCOL RREZE Located on boom head P N 9114 3290 MYSTIK TETRIMOLY MYSTIKTETRIMOLY MYSTIK TETRIMOLY GREASE CHECK A WARNING READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL WHEN LIFTING PERSONNEL
8. Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling GRADALL 406 Mill Ave SW New Philadelphia Ohio USA 44663 Phone 330 339 2211 Fax 330 339 8468 http www gradall com Printed in USA
9. annually Use of your unit may vary significantly and you must adjust service frequency for your usage to obtain maximum service life Frequency headings in the following schedule indicate a calendar limit and an operating hour limit Perform service at whichever interval occurs first Lube No of Symbol Points Daily or Shift 10 hour Maximum Lubrication amp Maintenance 9 Fuel Filler Cap fill at end of work shift to minimize condensation DF 1 10 Hydraulic Return Filter Condition Indicator check with oil at normal operating temperature and engine running at full throttle replace element before by pass indication is reached or at least annually 1 11 Hydraulic Suction Filter replace filter element when return filter element is replaced 1 13 Hydraulic Level Sight Gauges level handler retract all other cylinders and check sight gauges refill as required HF 1 21 Air Cleaner Element Condition Indicator check for clogged condition red band showing and clean or replace element as required item 28 is air cleaner Note If equipped with safety small element change it every 3rd change of primary large element L 34 Engine Crankcase Dipstick level handler and check level refill as required item 36 is filler cap EO 1 Weekly or 50 Hour Lubrication amp Maintenance include all previous periodic services 1 Stabilizer Cylinder Pivots HM 4 4 Sway Cylinder Pivots HM 2 7 Battery
10. inching slow travel functions overlap some features of inching will be discussed here See Drive Train Section page 10 0 for additional information on inching travel See Figure 3 1 for layout of controls Inching Travel Overlap between braking and inching occurs because the same pedal controls both functions also because both functions control travel speed However the methods of controlling travel speed are quite different Service braking involves a controlled stopping force applied to the front wheels Inching involves a controlled driving force applied to the driving wheels Figure 7 1 _ SERVICE BRAKE INCHING A TRAVEL PEDAL HIGHEST INCHING TRAVEL SPEED _ LOWEST INCHING TRAVEL SPEED _ N 7f SERVICE BRAKING Most of the inching travel pedal stroke controls the speed of inching travel As the pedal nears the bottom of its stroke service brakes are engaged Service Brakes Depressing service brake inching travel pedal to braking portion of pedal travel causes controlled hydraulic pressure to be applied to service brakes The greater the pedal travel the greater the braking force If power assist fails it will require much greater force on pedal to apply brake and stopping distance will be greater Parking Brakes The parking brakes are spring applied and hydraulically released Hydraulic power to release parking brakes is provided by the hydraulic system and is controlled by the parking brake
11. Gradall Material Handlers GRADALT Do not use the Personnel Work Platform until you study amp understand the Capacity Chart If your handler does not have the correct Personnel Work Platform Capacity Chart ask your supervisor to get one before using the attachment Do not use a boom mounted winch while the platform is mounted to the boom 14 0 OBTAINING HYDRAULIC OIL SAMPLE 8 9 Operate unit until hydraulic oil reaches normal operating temperature Apply parking brake lower boom to ground and shift Forward Reverse lever to Neutral Observe Hydraulic Filter Bypass Indicator with engine running at full throttle Replace filter elements if necessary Obtain a container to receive waste oil and a CLEAN container to receive oil sample With gauge removed from hose attach mini check and hose to test port near right wall of engine compartment Hose end must be positioned in waste oil container Allow at least one pint of oil to flow into waste oil container to eliminate any contamination from hose Move hose to CLEAN container to collect sample for analysis Return hose to waste oil container and disconnect adapter from mini check test port Cover sample container immediately with CLEAN cap Stop engine and check oil level in reservoir and replenish as required 10 Contact your GRADALL Distributor for information concerning oil analysis Oil sample containers are availa
12. P N 9116 3212 Form No 20219 534D 9 534D 10 Owner Operator Manual GRADALL IN THE USA NL 7733 3027 Located on left cab wall P N 7733 3027 INSIDE THE CAB WARNING NO RIDERS PERMITTED ON HANDLER OPERATOR ONLY IN MACHINE WHILE RUNNING RIDERS COULD FALL OFF MACHINE CAUSING SERIOUS INJURY OR DEATH 9114 3283 Located on left cab wall P N 9114 3283 ATERIAL HANDLER LE COMPANY MODEL 534D9 45 SERIAL NO ENGINE SERIAL NO WEIGHT 23 570 LBS AS RELEASED FROM FACTORY THIS TRUCK MEETS THE DESIGN SPECIFICATIONS ESTABLISHED IN AMERICAN NATIONAL STANDARDS FOR POWERED INDUSTRIAL TRUCKS PART lI ASME B56 6b 1998 CAPACITY WITH STANDARD 48 66 amp 72 CARRIAGE 9 8 T 36 FT 40 45 FT 24w 24 24 24 iN 23r 48 CARRIAGE PIN 9045 5051 55 CARRIAGE IN 9045 5082 72 CARRIAGE IN 9085 5008 SRO BUCKET 9045 5049 Ti YD BUCKET IN 9086 5020 WORK PLATFORM PIN 90558024 TRUSS BOOM PIN 9045 5011 TRUSS BOOWWIWINCH PIN 9045 5012 26 100 40 F 24 24m 8757 Lua 26 450 40 Fr 24m 24 8 7 FT 25 380 42 amp 24w 24m 27 25460 42 24 24w 25 EN soassa S 2516
13. PURGE AIR BY OPENING DE AERATION PETCOCK WHILE ENGINE IS RUNNING Located on engine Cummins Engines Only P N 9116 3256 HYDRAULIC OIL LEVEL FULL ADD CHECK OIL LEVEL WITH HANDLER LEVEL AND ALL CYLINDERS RETRACTED 1 GALLON BETWEEN ADD AND FULL MARKS 9116 3130 Located on hydraulic reservoir P N 9116 3130 TEST PORTS IMPLEMENT nee CHARGE Located on hydraulic filter bracket P N 9114 3162 2 4 OUTSIDE THE CAB A WARNING EXHAUST SYSTEMS CAN BE HOT KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT HOT EXHAUST COMPONENTS CAN CAUSE SEVERE BURNS Located on engine compartment P N 9114 3280 JUMP STARTING INSTRUCTIONS WHEN JUMP STARTING MATERIAL HANDLER NEVER ALLOW VEHICLES TO TOUCH CONNECT THE POSITIVE JUMPER CABLE TO POSITIVE POST OF DISCHARGED BATTERY CONNECT OPPOSITE END OF POSITIVE JUMPER CABLE TO POSITIVE POST OF BOOSTER BATTERY CONNECT THE NEGATIVE JUMPER CABLE TO NEGATIVE POST ON BOOSTER BATTERY CONNECT OPPOSITE END OF NEGATIVE JUMPER CABLE TO GROUND POINT ON MACHINE AWAY FROM DISCHARGED BATTERY FOLLOW STANDARD STARTING PROCEDURES REMOVE CABLES IN REVERSE ORDER AFTER MACHINE HAS STARTED 9114 3285 CAUTION COOLING SYSTEM IS PRESSURIZED REMOVE CAP SLOWLY HOT FLUID CAN CAUSE BURNS 8060 3026 Located on engine cover P N 8060 3026
14. USE ONLY A GRADALL MANUFACTURED THIS CHART MUST BE USED IN CONJUNCTION WITH SERVICE MANUAL AND RECOMMENDED PROCEDURE ON HYDRAULIC FILTER CHANGE FILTER IF NEEDLE IS IN YELLOW PERSONNEL WORK PLATFORM AT FULL THROTTLE amp AT OPERATING TEMPERATURE ALL PERSONNEL IN PLATFORM MUST WEAR A FULL BODY HARNESS WITH CHECKAIR CLEANER RESTRICTION INDICATOR CLEAN OR CHANGE PRIMARY FILTER NECESSARY LANYARD ATTACHED TO A DESIGNATED ANCHORAGE POINT SAFETY ELEMENT TO BE CHANGED EVERY 3RD CHANGE OF PRIMARY FILTER ELEMENT READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER S MANUAL CONSULT DEALER FOR RECOMMENDATIONS AT EXTREME TEMPERATURES BEFORE OCCUPYING PERSONNEL WORK PLATFORM 44 DAILY SERVICE MAY BE REQUIRED FOR OPTIMUM LIFE DEPENDING UPON APPLICATION SEVERITY IT IS RECOMMENDED THAT FILTER ELEMENTS AND FRONT AXLE LUBRICANT BE CHANGED AFTER FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH FIRST 50 HRS ON NEW OR REBUILT UNITS 9134 3073 REV 9055 3026 REV A Located on mudguard Located on boom head P N 9134 3073 P N 9055 3026 A WARNING READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM ATTACH LANYARD HERE DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM 9055 3032 WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN CAB WITH PERSONNEL IN DIRECT
15. WHILE MACHINE 1 IN MOTION STATIC BRAKE ONLY 9114 3182 Located on dashboard P N 9114 3182 CAPACITY CHART MODEL 534D 9 USE CAPACITY CHART FOR SPECIFIC ATTACHMENT ON MACHINE FOR OTHER ATTACHMENTS CONSULT A GRADALL DEALER FOR LOAD RATINGS NOT LISTED EST NUMBER VISIBLE FROM THE CAB TO EXTENSION E TO DETERMINE ALLOWABLE LOAD PACITY TRUCK LEVEL RATED LIFTING MACHINE ON A FIRM LEVEL SURFACE WITH MACHINE SPECIFICATIONS AND S CAPACITIES AT SPECIFIC BOOM ANGLI IF SPECIFICATIONS ARE CRITICAL THE PROPOSI SHOULD BE DISCUSSED WITH YOUR DEALER DO NOT EXCEED RATED LIFT CAPACITY LOADS AS UNSTABLE DANGEROUS MACHINE CONDITIONS WILL RESULT DO NOT TIP THE MACHINE FORWARD TO DETERMINE ALLOWABLE LOAD CERTAIN CARRIAGE FORK COMBINATIONS MAY CAUSE HANDLER TO TIP WITHOUT LOAD WHEN EXTENDED INTO NO OPERATION ZONE AS NOTED ON CAPACITY CHART CAPACITY LIMITS FOR THIS UNIT ARE BASED IN ACCORDANCE WITH STANDARDS LISTED ON SERIAL NUMBER PLATE LEVEL GRADALL HANDLER BEFORE LIFTING ABOVE 4 FT 9134 3005 REV B Located on dashboard P N 9134 3005 MACHINE MUST BE IN NEUTRAL AND PARK BRAKE ON TO START Located on dashboard P N 9114 3120 gt 4 4 N gt IN lt 9102 3006 Located on seat pedestal P N 9102 3006 2 1 INSIDE THE CAB TRACTION LOCK SWITCH SWITCH LOCATED DO NOT ENGAGE ON FLOO
16. anyone is injured by hydraulic fluid including penetration into the skin obtain medical help immediately 5 0 WARM UP amp OPERATIONAL CHECKS To be performed at beginning of each work shift The safety efficiency and service life of your handler will be increased by performing the operational checks listed below If any of the items in the following checks are not operating properly have them repaired prior to the machine being placed into service Items preceded by an asterisk are optional and may not be furnished on a standard machine Before entering the operator s cab check 1 Air Filter Restriction Indicator If needle is red area filter is clogged and element must be changed During warm up period check 2 Heater defroster and windshield wiper 3 Operating lights and rotating beacon 4 Voltmeter should show 13 5 to 14 volts When engine warms to operating range check 5 Service brake and parking brake 6 Forward and reverse travel 7 Steering stop to stop in both directions with engine at low idle 8 Inching travel should be smooth through full pedal travel 9 Horn and back up alarm 10 All boom and attachment functions operate fully and correctly CAUTION 11 Hydraulic level sight gauge level handler retract all cylinders and check sight gauge for hydraulic fluid level refill as required Continued operation with hydraulic fluid bypassing the filter may cause severe damage to
17. has started Form No 20219 534D 9 534D 10 Owner Operator Manual Operator must be seated with seat belt fastened forward reverse lever in Neutral position parking brake applied and all hydraulic controls in Neutral before starting engine Turning ignition switch to START position while engine flywheel is rotating may cause serious damage to engine and or starting motor NOTE Engine will not start unless forward reverse lever is in Neutral and parking brake switch is applied If you use a starting aid employing ether or a similar substance pay particular attention to manufacturer s warnings Excessive ether may cause severe engine damage 6 1 Normal Engine Operation Observe gauges frequently to be sure all engine systems are functioning properly The voltmeter shows the charge discharge state of the battery charging system With the engine running meter should indicate 13 5 to 14 volts With engine stopped meter indicates battery charge 12 volts The alternator indicator light glows red to indicate alternator is not charging Be alert for unusual noises or vibration When an unusual condition is noticed park machine in safe position and perform standard shut down procedure See Page 1 1 Report condition to your supervisor or maintenance personnel Avoid prolonged idling Idling causes engine temperature to drop and this permits formation of heavy carbon deposits and dilution of lubricating oil b
18. hydraulic system 12 Hydraulic Filter Condition Indicator observe engine coolant temperature components gauge after starting normal operation When needle has been in operating range for an hour or so stop handler in a safe area apply parking brake lower attachment fully shift forward reverse lever to Neutral position and block wheels With engine running at full throttle have an assistant check the Hydraulic Filter Condition Indicator When needle is in red area filter is clogged and hydraulic oil is bypassing filter Filter element must be changed before needle reaches red area Complete all required maintenance before operating unit 6 0 ENGINE OPERATION Starting the Engine 1 Make sure all controls are in Neutral and all electrical components lights heater defroster etc are turned off Set parking brake 2 Depress accelerator pedal approximately 1 4 to 1 3 of travel from top 3 Turn ignition switch to START to engage starting motor Release key immediately when engine starts If engine fails to start within 20 seconds release key and allow starting motor to cool for a few minutes before trying again 4 After engine starts observe oil pressure gauge If gauge remains on zero for more than ten seconds stop engine and determine cause Correct malfunction before restarting engine Minimum pressure at operating temperature Low idle 10 PSI 69kPa 5 Warm up engine at approximately 1 2 th
19. load Tag lines must be long enough to keep helpers clear of load and handler e Beware of wind Wind can cause a suspended load to swing and cause dangerous side loads even with tag lines e Start travel turn and stop slowly to prevent load from swinging e Weight of all rigging slings etc must be included as part of load Do not attempt to use handler frame leveling to compensate for load swing Attachment Tilt Controls Figure 13 6 LOWER WINCH LOAD The auxiliary control lever is used to control AUXILIARY the boom head mounted winch Pull the CONTROL LEVER lever back to raise winch load push the RAISE lever forward to lower winch load WINCH LOAD Installation Procedure 1 Install winch on boom head and connect hydraulic hoses at winch motor 2 Position winch hook directly above balance point of load and secure using appropriate rigging Operation e Attach tag lines to load and transport load to delivery site e While helpers guide load with tag lines position load at delivery point Form No 20219 534D 9 534D 10 Owner Operator Manual A side load or a swinging load could cause the handler to tip over and or damage the boom PRECAUTIONS Maximum winch load capacity is reduced from normal carriage fork load rating Always level handler before lifting a load See Page 11 0 Travel with load and boom lowered to travel position load 4 feet 1 2m or less above the ground e Always lo
20. of the load as close to the heel of the forks as possible In all cases the load center must be centered between the forks Load Limits Some capacities shown on the rated capacity chart are based on machine stability and some are based on hydraulic lift capacity The common sense or feel an experienced operator might apply in regard to tipping loads DOES NOT APPLY to hydraulic load limits Exceeding load limits can cause damage or in some cases cause the machine to tip over Form No 20219 534D 9 534D 10 Owner Operator Manual All loads shown on rated capacity chart are based on machine being on firm level ground the forks being positioned evenly on carriage the load being centered on forks proper size tires being properly inflated and the handler being in good operating condition 12 2 Items needed to Use a Capacity Chart There are five items you must know and or have in order to properly use a Capacity Chart The weight of the load to be lifted The angle of the boom How much boom extension will be needed The proper Capacity Chart A Gradall approved Attachment Or e U N Every Gradall attachment comes with its own Identification Plate This Plate has the Attachment Serial Number Part Number Attachment Capacity and Attachment Weight stamped on it Make sure that the Capacity Chart you are using matches the attachment exactly This may be done by matching the attachment part number on the Capacity C
21. 250 hrs 1 8 t t T t Jam Nut 5 Weeks 250 hrs e 100 110 137 EE Wheel Lug Nuts 3 Months 500 hrs Check torque at whichever interval occurs first t Refer to appropriate Service Manual for procedure to check and adjust cables 17 3 BOOM CHECKING amp ADJUSTING BOOM CABLES Boom is extended by a cylinder and a pair of cables within the boom For more detailed information including boom cable checks and adjustments see the appropriate Service Manual STABILIZER Stabilizers are furnished as standard equipment on all 534D 10 Material Handlers Use stabilizers to increase stability and or load capacity and in leveling the handler before picking or delivering a load Study load charts carefully to determine maximum load capacities for various lift situations with and without stabilizers Before using stabilizers to support handler load on untested surface perform following procedure 1 With handler positioned to pick or deliver load and with load on ground or pick point lower stabilizers enough to level handler and remove weight from front wheels 2 If required position signal man to observe and report penetration of stabilizer shoes in supporting surface 3 With forks beneath load slowly begin to raise load Stop immediately if signal man reports excessive or uneven shoe penetration If shoe penetration is acceptable proceed with lift If stopped by signal man relieve load from forks and procee
22. 33 24m 24m L 7 E SLOPE 246 0 32 24m 24m 45er EX Ia JL 9 24750 32 rr 24m 24m terr WEIGHTS ARE BASED ON USING 1 3 4 X 6 X 48 FORKS APPROX 3608 PER PAIR BUCKET DIMENSIONS A amp 0 REFER TO BUCKET LIP HEIGHT JSS BOOM WINCH amp QUICK HOOK DIMENSIONS A 4 D REFER TO HOOK CENTER IGHT IS BASED ON SPL SWING MAST FORKS 48 APPROX 220 PER PAIR APPROX 4906 PER PAIR TFORM DIMENSIONS 4 D REFER TO CENTER OF FLOOR FORKS RATED LESS THAN THE ATTACHMENT CAPACITY SHOWN ABOVE DECREASE CAPACITY OF ATTACHMENT TO THAT OF FORKS FORKS RATED MORE THAN ATTACHMENT CAPACITY DO NOT INCREASE ATTACHMENT CAPACITY 134 3062 REV D Located on right cab wall P N 9134 3062 534D 9 P N 9135 3210 534D 10 SD 57201 GRADALL MATER 06 9 10 MAX WEIGHT 2150 MEETS SAE J1040 MA MEETS ISO 3471 94 3 MEETS ANSI B56 6 8 16 P GRADALL SERIAL Located on left side front cab plate P N 9116 4097 enclosed cab P N 9116 4093 open cab WARNING THE PROTECTION OFFERED BY THIS ROPS WILL BE IMPAIRED IF IT HAS BEEN SUBJECTED TO ANY MODIFICATION STRUCTURAL DAMAGE OR HAS BEEN INVOLVED IN AN OVERTURN INCIDENT THIS ROPS MUST BE REPLACED AFTER A ROLL OVER SEAT BELTS MUST BE WORN WHILE OPERATING VEHICLE V 000850 Located on left side front cab plate P N 9116 4094 ENGINE OIL LEV
23. Cap check and clean or replace cap as required 24 Boom Bottom Front Slide Bearings to be performed by experienced maintenance person check for damage and excessive wear no wear permitted past bevel maximum clearance at top bearing is 1 8 inch 3mm shim or replace as required when these bearings require service check all other slide bearings shims are 1 16 inch 1 5mm thick 25 Boom Top Side and Bottom Rear Slide Bearings extend boom fully and lube all wear paths retract and extend boom fully three times and wipe excess lube from bearings 27 Boom Extend Cables check and adjust as required 29 Vacuator Valve rubber cone on bottom check to be sure cone is clear and undamaged 33 Engine Oil Filter replace filter element 41 Drive belts check condition replace as required 42 Engine Crankcase Drain Plug drain and refill to level 45 Rear Hub Level Plug check level and refill as required HF HM HM EO HF No of Check torque of all items listed in Torque Chart pg 17 2 Quarterly or 500 Hour Lubrication amp Maintenance include all previous periodic services 12 Hydraulic System we recommend that hyd fluid be analyzed to determine condition drain and refill reservoir if required 14 Hydraulic Reservoir Screen remove clean and install when hydraulic oil is drained 35 Fuel Strainer replace 44 Fuel Filter Water Separator with Drain replace filter element Hd
24. DALL Distributor to determine capacity limitations Other Attachment Capacities A serial number capacity plate is attached to all GRADALL furnished attachments Do not assume that any GRADALL attachment may be used on any GRADALL Material Handler First check the listing of approved attachments on handler serial number plate If the attachment in question is not included in the list contact your local GRADALL Distributor to check whether or not the attachment is approved Next if the attachment is approved for use with your handler compare maximum capacity from attachment serial number plate and value stamped on forks to maximum capacity for that attachment as indicated on material handler serial number plate The smallest of these values is correct for your handler Attachments which have not been approved for the use with your handler could cause machine damage or an accident resulting in injury or death The capacity of forklift attachment and fork combination may be less than the capacity shown on attachment Consult forklift nameplate and also ensure forks are of proper size Forks rated less than the attachment capacity decrease capacity of attachment to that of forks Forks rated more than attachment capacity do not increase attachment capacity Never use an attachment without the appropriate GRADALL supplied capacity chart for that particular attachment installed in the handler 13 1 Attachm
25. EL 9114 3292 Located on right cab wall Cummins Engines Only P N 9114 3292 A WARNING 1 ONLY TRAINED AND AUTHORIZED PERSONNEL MAY OPERATE THIS MACHINE 2 BEFORE OPERATING READ AND UNDERSTAND ALL CAPACITY CHARTS OPERATOR MANUALS AND SAFETY MANUALS IF MANUALS ARE NOT AVAILABLE CONSULT AN AUTHORIZED GRADALL DEALER UNDERSTAND ALL CONTROLS IN CAB AND CHECK FOR PROPER OPERATION CLEAR LOOSE OBJECTS OFF MACHINE AND SOUND HORN BEFORE STARTING ENGINE 3 OPERATOR MUST BE SEATED WITH SEAT BELT FASTENED ASSURE FORWARD REVERSE LEVER IS IN NEUTRAL PARK BRAKE APPLIED AND ALL HYDRAULIC CONTROLS ARE IN NEUTRAL BEFORE IGNITION SWITCH IS TURNED ON 4 DO NOT OPERATE MACHINE WITHOUT PROPER CAPACITY CHART IN PLACE 5 BEFORE MOVING BE SURE OF A CLEAR PATH AND SOUND HORN WATCH FOR PEDESTRIANS AND OBSTRUCTIONS CHECK OVERHEAD AND SIDE CLEARANCES ALWAYS LOOK IN DIRECTION OF TRAVEL 6 START TURN AND BRAKE SMOOTHLY REDUCE TRAVEL SPEEDS FOR TURNS SLIPPERY OR UNEVEN SURFACES AVOID RUNNING OVER LOOSE OBJECTS OR HOLES IN THE ROADWAY SURFACE FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF SERIOUS INJURY READ AND OBSERVE THE FOLLOWING 7 WHEN TRAVELING WITH LOAD FULLY RETRACT BOOM AND PLACE FORKS IN CARRY POSITION TILT CARRIAGE BACK SLIGHTLY TO CRADLE LOAD USE EXTREME CAUTION WHEN TURNING 8 ON INCLINES TRAVEL WITH LOAD UP GRADE 9 DO NOT USE BOOM AS WALKWAY 10 USE TWO HANDS WHEN CLIMBING ON MACHINE
26. Er a eR nitas STEERING SYSTEM DRIVETRAIN cie eA LEVELING THE HANDLER DE TNE OPERATING PROCEDURE amp TECHNIQUES Hydraulic Controls Rated Capacity Chart ATTACHMENTS 13 0 Approved Attachments Non Approved Attachments Carriage Fork Capacities Other Attachment Capacities Attachment Installation Attachment Operation Nr 0 ooo OBTAINING HYDRAULIC OIL SAMPLE FOR ANALYSIS 14 0 LOADING amp SECURING FOR 15 0 MOVING HANDLER IN Henn 16 0 Moving Short Distances Moving Longer Distances To Activate Tow Bypass To Release Parking Brake To Restore Parking Brake MAINTENANCE SECTION erue rena rar rn center 17 0 Nomenclature Lubrication and Maintenance Lubrication Chart Torque Chart Boom Stabilizer INSPECTION AND MAINTENANCE LOG 18 0 I IPESIIS P cce inside back cover INTRODUCTION General This Manual provides important information regarding safe operating and maintenance requirements for GRADALL Material Handlers If you have any questions regarding the material handler contact your GRADALL Material Handler Distributor Opera
27. LINE OF SIGHT OPERATE CONTROLS LIGHTLY AND CAUTIOUSLY WHEN LIFTING PERSONNEL READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER S MANUAL BEFORE LIFTING PERSONNEL Located on Pe rsonn el Wo rk PI atfo rm DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL HANDLER PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN CAB FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH P N 9 0 5 5 3 03 2 9055 3027 REV A Located on mudguard P N 9055 3027 A WARNIN MAXIMUM OCCUPANCY THREE 3 PEOPLE DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL HANDLER PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN CAB FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH 9055 3031 REV A Located on left side of boom Located on Personnel Work Platform P N 9100 3031 P N 9055 3031 9 GRADALL _ 2 GRADALL ES SERIAL NUMBER SERAL NUMBER WEIGHT WEIGHT CAPACITY CAPACITY HYD PRESSURE HYD PRESSURE AND ALSO INSURE FORKS ARE Q 9055 3033 Located on attachment Located on Personnel Work Platform P N 9015 3001 P N 9055 3033 Form No 20219 534D 9 534D 10 Owner Operator Manual 3 0 OPERATOR S CAB OPERATOR S CAB The standard cab permits vision from all sides and includes an overhead guard to provid
28. R SWITCH WHEN WHEELS ARE HYDRAULICALLY IN MOTION OR LOCKS FRONT AND ON IMPROVED REAR WHEELS SURFACES MACHINE TOGETHER FOR MUST BE IN 4 INCREASED TRACTION WHEEL DRIVE 9108 3314 Located on dashboard P N 9108 3314 STARTING AID INSTRUCTIONS HOLD SWITCH ON FOR 3 SECONDS TO FILL VALVE RELEASE SWITCH TO DISCHARGE ETHER WHILE CRANKING ENGINE 3 AS ENGINE STARTS USE ADDITIONAL ETHER AS REQUIRED TO KEEP ENGINE RUNNING N a 9114 3202 Located on dashboard Cummins Engines Only P N 9114 3202 NEUTRALS REVERSE Located on forward reverse lever P N 9116 3028 FORWARD Located on lever knob P N 9108 3318 3 CAUTION TURBOCHARGER DAMAGE CAN RESULT FROM QUICK START UP amp SHUTDOWN FOR LONGER TURBOCHARGER LIFE AND TO MINIMIZE TURBOCHARGER DAMAGE IDLE ENGINE AT LEAST 3 5 MINUTES AFTER START UP AND BEFORE SHUTDOWN 9134 3016 Located on dashboard P N 9134 3016 BOOM JOYSTICK OPERATION 9130 3047 Located on joystick pedestal P N 9130 3047 Located on lever knob P N 9108 3317 WARNING CERTAIN FORK CARRIAGE COMBINATIONS MAY CAUSE HANDLER TO TIP WHEN EXTENDED INTO NO OPERATION ZONE AS NOTED ON CAPACITY CHART WITH STABILIZERS UP CAUSING SERIOUS INJURY OR DEATH NEVER OPERATE MACHINE WITHOUT CONSULTING PROPER CAPACITY CHART FOR THE CARRIAGE FORK COMBINATION BEING USED 9116 3212 Located on dashboard
29. RADALL reserves the right to change specifications without notice Gradall is a registered trademark for Hydraulic Excavators Hydraulic Material Handlers and Attachments manufactured by The Gradall Company REVISIONS This page is provided so you may determine that this Manual is complete and current with respect to Gradall Engineering Specifications Form No 20219 534D 9 534D 10 Owner Operator Manual TABLE OF CONTENTS IMPORTANT SAFETY NOTICE beast das inside front cover TABLE OF CONTENTS INTRODUCTION General Operator Qualifications Orientation Related Manuals amp Decals Serial Number Location NOMENCLATURE SAFELY HIGFLIGELTS Liiesisoexesdeks3aeueu si a x DECALS Decals Inside Cab Decals Outside Cab OPERATORS 3 Cab Control amp Instrument Identification CHECKS amp SERVICES BEFORE STARTING ENGINE WARM UP amp OPERATIONAL CHECKS ENGINE OPERATION Starting the Engine Cold Weather Starting Aids Battery Boosted Starting Normal Engine Operation Stopping the Engine John Deere Engine Shut Down Protection Feature STEM exor utr HER sd aeo pup UU IRE RUNE 7 0 General Inching Travel Service Brakes Parking Brakes PARKING THE HANDLER Fr
30. T i a MACHINE LEVEL MEI AUXILIARY CONTROL LEVER Hour 2 4X4 INDICATOR LIGHT OPTIONAL METER le ALTERNATOR INDICATOR LIGHT lt ATTACHMENT TILT SWITCH PARK BRAKE SWITCH OPTIONAL HORN BUTTON SCOR LIGHT IGNITION BOOM CONTROL JOYSTICK SWITCH CHECK ENGINE LIGHT DEERE ENGINES ONLY ATTACHMENT TILT LEVER SERVICE BRAKE INCHING TRAVEL PEDAL STABILIZER TRACTION LOCK CONTROL LEVERS eer m MACHINE D 10 ONLY ACCELERATOR LEVEL LEVER PEDAL Never operate the handler unless the overhead guard is in place and in good condition Any modification to this machine must be approved by GRADALL to assure compliance with FOPS ROPS certification for the cab machine configuration NOTE Relevant S A E Recommended Practices S A E J1040 for ROPS S A E J231 for FOPS 3 1 Accelerator Pedal Depress pedal to increase speed and release pedal to decrease speed Alternator Indicator Light Glows red to indicate alternator is not charging Attachment Tilt Lever This lever controls tilt of the fork carriage Speed is proportional to lever actuation and engine RPM Push lever forward to tilt down pull lever back to tilt up Attachment Tilt Switch optional Depress front of switch to tilt down depress rear of switch to tilt up Auxiliary Control Lever optional This lever is used to control optional hydraulic attachments Follow deca
31. THAN THEY APPEAR 9055 3028 REV A Located on right cab wall P N 9055 3028 2 3 OUTSIDE THE CAB 1995 Signa Tek Inc A WARNING DO NOT GO NEAR LEAKS High pressure oil easily punctures skin causing serious injury gangrene or death If injured seek emergency medical Immediate surgery is required to remove oil A Do not use finger or skin to check for leaks Lower load or relieve hydraulic pressure before loosening fittings Located on valve access cover in cab Located on hydraulic reservoir P N 9108 3492 GRADALL Genuine Parts HYDRAULIC SYSTEM FILL WITH TRACTOR HYDRAULIC FLUID Mobilfluid 424 or equivalent For Mobil Product Information Call 1 800 662 4525 9114 3288 Located on hydraulic reservoir P N 9114 3288 WARNING STAY CLEAR OF MOVING PARTS WHILE ENGINE IS RUNNING MOVING PARTS CAN CAUSE SERIOUS INJURY 9114 3281 Located on sheet metal cover of hydraulic reservoir and fuel tank P N 9114 3281 A WARNING STAY CLEAR OF PINCH POINT AREA ANYTIME ENGINE IS RUNNING BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH 9114 3282 Located on right and left rear frame hydraulic reservoir amp boom head P N 9114 3282 Form No 20219 534D 9 534D 10 Owner Operator Manual ATTENTION WHEN REPLACING COOLANT OR IN CASE OF COOLANT LOSS
32. The operator may delay a shutdown for 30 seconds by pushing the Shutdown Override switch The switch resets the shutdown timer to 30 seconds and may be used repeatedly However continuously holding the Shutdown Override switch will not reset the 30 second timer Stabilizer Control Levers D 10 only Left lever controls left stabilizer right lever controls right stabilizer Push levers forward to lower stabilizers pull levers back to raise stabilizers Starting Aid Switch Cummins Engines Only This switch engages and disengages the cold weather starting aid if your handler is so equipped Steering Wheel The steering wheel controls the angle of rear wheels Turning the steering wheel to the right causes a right turn by angling rear wheels to left A left turn is caused by angling rear wheels to right Traction Lock Pedal This pedal operates traction lock valve which functions to restore traction when a wheel spins in four wheel drive Voltmeter This gauge indicates alternator output and battery condition 4x2 4x4 Switch This switch engages and disengages rear wheel drive motors Rear drive motors are engaged for four wheel drive 4x4 Indicator Light Glows amber to indicate four wheel drive is engaged When park brake is applied this light will not glow 4 0 CHECKS amp SERVICES BEFORE STARTING ENGINE To be performed at the beginning of each work shift If spark arrestors are required be sure they ar
33. a soft or uneven surface Always look in the direction of travel Reduce speed and be especially careful when traveling in reverse and or turning Be aware of tail swing due to rear pivot steering If load or conditions obstruct view use a signal person when lifting carrying or placing a load Loose clothing can get caught in moving machinery and can also cause accidental actuation of controls Dress properly for the job Be alert to any unusual response to controls If unusual response is noticed position handler in a safe area lower forks to ground apply parking brake stop engine and remove key from ignition switch Tag steering wheel to forbid operation and notify maintenance personnel Keep hands gloves shoes control knobs and pedals clean Slippery controls can cause accidents Keep a firm grip on the steering wheel when traveling Load capacities are based on load center being within 24 inches 610mm from front vertical face of forks Never service the handler with the engine running Release trapped pressure before disconnecting opening or removing any hydraulic component WATCH FOR THESE SYMBOLS THEY CALL YOUR ATTENTION TO SAFETY NOTICES This symbol indicates an extreme hazard which will result in high probability of death or serious injury if proper precautions are not taken This symbol indicates a hazard which could result in death or serious injury if proper precautions are not ta
34. age fork combination or other attachment from boom head See Page 13 1 2 Install swing mast on boom head and connect auxiliary hydraulic hoses to swing mast diversion valve hoses Also connect electrical cable at boom head Operation e Always lower carriage fully in mast and position forks straight ahead before engaging load e To travel with a load keep forks straight ahead and lower load to travel position 4 feet 1 2m or less above ground e Inspect supporting surface at delivery point and have it leveled if necessary e Level handler before raising load e If necessary perform a dry run unloaded of delivery to determine best position for handler e Use a signal person to assist in positioning the load if necessary Form No 20219 534D 9 534D 10 Owner Operator Manual PRECAUTIONS Always level forks horizontally before swinging load to side Swinging unleveled forks may result in load slipping from forks The swing mast attachment has a smaller load capacity than the standard carriage fork attach Study and understand the swing mast capacity chart before handling a load with swing mast e Read additional capacity information under Capacity heading on chart e Because the swing mast increases lift height and can swing load to side it is especially important to level handler before lifting a load more than four feet 1 2m above ground level See Page 11 0 Do not handle a load with Swi
35. al Handlers There are no stabilizers on the 534D 9 Form No 20219 534D 9 534D 10 Owner Operator Manual 17 1 LUBRICATION amp ROUTINE MAINTENANCE Figure 17 2 SYMBOLS e Lube Fitting Other Service Service Both Sides Lubrication Symbols ANTI FREEZE permanent COOLANT CONDITIONER DIESEL FUEL ENGINE FUEL HYDRAULIC FLUID MOLY LUBE extreme pressure 25 IMPORTANT NOTICE FAILURE TO USE GRADALL Be certain to check extend cable ad justment every 5 weeks or 250 HYDRAULIC FILTER ELEMENTS hours and adjust as required Cable COULD VOID WARRANTY damage can occur if cable is not ad justed properly 17 18 33 34 35 36 LUBRICATION NOTICE lint free cloth Apply light coating of engine oil to all linkage pivot points Clean lubrication fittings before lubricating Intervals shown are for normal 8 hour day usage and conditions Adjust intervals for abnormal usage and conditions Drain engine and gear cases after operating when oil is hot Check lubricant levels when lubricant is cool Clean filter and air cleaner housing and reusable elements using solvent or diesel fuel Dry components thoroughly using 4p 46 A CAUTION Service intervals are based on machine usage of 1500 hours
36. and instruction plates can be ordered from your GRADALL Material Handler Distributor Models Covered This Manual covers basic information for Gradall Material Handlers Detailed information for each particular machine is in the maintenance section in the back of this manual Be certain to refer to proper information for your unit and the operational equipment furnished on your machine Serial Number Location Specify Model Number and Serial Number when ordering parts and when discussing specific applications and procedures with your Distributor The model serial number plate is located inside the operator s cab right wall See Figure I 2 Form No 20219 534D 9 534D 10 Owner Operator Manual NOTE Material handler and handler are used interchangeably throughout this Manual NOTE Though no offense or discrimination is intended only the masculine pronouns will be used throughout the remainder of this Manual LEFT Figure 1 1 GRADALL MATERIAL ALE COMPANY MODEL 534D9 45 SERIAL NO CUMMINS CPL NO WEIGHT Les 23 570 LBS Figure I 2 1 0 SAFETY HIGHLIGHTS Read and understa
37. ble from several sources Oil companies Oil suppliers e Sampling labs Form No 20219 534D 9 534D 10 Owner Operator Manual TAKE HYDRAULIC SAMPLE FROM THIS PORT NOTE OIL CLEANLINESS IS CRITICAL The filtration system is designed to maintain a minimum ISO cleanliness level of 18 15 15 0 LOADING amp SECURING FOR TRANSPORT Loading amp Securing Handler For Transport 1 Level the material handler prior to loading 2 Using a spotter load the handler with boom as low as possible to keep a low center of gravity 3 Once loaded apply parking brake and lower boom until boom or attachment is resting on deck Move all controls to Neutral stop engine and remove ignition key 4 Secure machine to deck by passing chains through two tie down lugs on front and rear of machine See Figures 15 1 amp 15 2 5 Do not tie down front of boom Figure 15 1 Figure 15 2 GRADALT Before loading handler for transport make sure deck ramps and handler wheels are free of mud snow and ice Failure to do so could cause handler to slide resulting in an accident causing serious injury or death NOTE Machine depicted may not be model covered by this manual however tie down locations are similar 16 0 MOVING HANDLER IN EMERGENCY The following information assumes the handler cannot be moved under its own power Before moving the handler read all of the following information to understand options a
38. bold line separating capacity regions the smaller of the two values must be used The regions are clearly marked with heavier outlines as shown on page 12 3 If you do not have the correct capacity chart for your machine and or attachment contact your Distributor or Gradall to order one Example A contractor has purchased a 534D 10 with the 48 Slope Piler Carriage Attachment See figure 12 5 He knows his attachment may be used with this model since the attachment part number 9108 5058 matches the attachment part number stamped on the machine Serial Number Plate He also knows that the Capacity Chart is correct since it is clearly marked for use with a 534D 10 and that the attachment he is using is listed at the bottom by part number He has determined the weight of the load to be lifted is 3000 Ibs and that he needs to place the load at a boom extension of 5 at a boom angle of 209 By tracing the boom extension arc down to where the 20 line intersects it the contractor can see that the maximum weight he can lift with stabilizers down is 4000 Ibs In this case he may lift the load NOTE Some attachments may not be approved for use with certain machine models 12 3 Figure 12 4 Where to look on the machine BOOM BOOM ANGLE EXTENSION INDICATOR NUMBER m 83490 45 7 ATTACHMENT IDENTIFICATION FORK WEIGHT STAMP
39. check terminals 1 8 Tires 4 534D 9 Standard 13 00 x 24 12 65 PSI 448 kpa 534D 10 Standard 14 00 x 24 12 ply 65 PSI 448 kpa Optional 14 00 x 24 Radial 70 PSI 482 kpa 15 Tie Rod Ends HM 2 16 King Pins HM 4 17 Steering Cylinder Rod Pivots HM 2 18 Steering Cylinder Barrel Pivots HM 2 19 Stabilizer Arm Pivots HM 4 20 Front Axle Pivot HM 2 22 Rear Axle Pivot HM 2 23 Carriage Tilt Cylinder Pivots HM 2 24 Boom Bottom Front Slide Bearings extend boom fully and lube all wear paths retract and extend boom fully three times and wipe excess lube from bearings HM 4 26 Extend Sheave Pin HM 2 30 Boom Lift Cylinder Pivots HM 4 31 Boom Head Carriage Pivot HM 2 32 Radiator Fill Cap check level and refill as required AF 1 37 Compensating Cylinder Pivots HM 2 38 Retract Cable Sheave HM 2 39 Boom Pivot HM 2 40 QuickSwitch Latch HM 1 44 Fuel Filter Water Separator with Drain drain water 1 At End of First 50 Hours Only 5 6 Planetary and Differential Drain Plugs drain and refill wait 5 minutes and fill again item 2 is level plug HF 3 At End of First 30 Days Only 250 Hours Maximum Lubrication amp Maintenance Check torque of all items listed in Torque Chart pg 17 2 Lube Symbol Points 5 Week or 250 Hour Lubrication amp Maintenance include all previous periodic services 2 Drive Axle Level Plug check level and refill as required 12 Hydraulic Reservoir Breather
40. cket is shown on the attachment serial number plate and may be used in areas where it does not exceed capacities shown on standard carriage fork capacity chart Capacity must be reduced for areas where maximum bucket capacity would exceed standard carriage fork capacity chart Attachment Tilt Controls Figure 13 2 LOWER LOWER LOWER RAISE BUCKET gt BUCKET BUCKET BUCKET LIP LIP LIP LIP RAISE RAISE BUCKET BUCKET LIP LIP Because the carriage tilt cylinder is used to tilt the bucket the carriage tilt lever is used to control the bucket Pull lever back to raise bucket lip push lever forward to lower bucket lip Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See Page 13 1 2 Install light material bucket on boom head 3 Retract boom fully and tilt bucket up or down as required to position bottom of bucket parallel with ground PRECAUTIONS e Always adjust fork position before engaging load e As with all other attachments handler must be level before handling a load more than four feet 1 2m above ground level See Leveling The Handler Page 11 0 Observe all precautions and load capacity limits listed previously when handling loads with carriage fork positioner PRECAUTIONS e Handler must be level before handling a load more than four feet 1 2m above ground level See Page 11 0 e Retract boom fully before loading bucket Loading buc
41. d with steps 4 and 5 4 With forks resting on ground raise stabilizers from surface far enough to install sufficient blocking to overcome excessive or uneven shoe penetration 5 Repeat steps 3 and 4 until excessive or uneven penetration has been overcome before lifting load Transport machine with stabilizers in the up position as shown in Figure 17 3 Form No 20219 534D 9 534D 10 Owner Operator Manual Stabilizers increase stability and load capacity ONLY if they are used properly Using stabilizers without regard to surface conditions could cause handler to tip over and result in serious injury or death Always ensure surface can support handler and load Figure 17 3 18 0 INSPECTION AND MAINTENANCE LOG HAND SIGNALS Standard Signals When handler work conditions require hand signals they shall be provided or posted conspicuously for the use of both signalman and operator No handler motions shall be made unless signals are clearly understood by both signalman and operator Special Signals When signals for auxiliary equipment functions or conditions not covered are required they shall be agreed upon in advance by the operator and signalman Instructions When it is desired to give instructions to the operator other than provided by the established signal system all handler motions shall first be stopped EMERGENCY STOP With both arms extended laterally hands open STOP With either a
42. e in place and in good working order Check to be certain that windows and mirror s are clean and undamaged Also make certain that mirror s are properly adjusted for operator s view Before removing filler caps or fill plugs wipe all dirt and grease away from the ports If dirt enters these ports it can severely reduce component life When adding fluids refer to lubrication section of Manual to determine proper type Complete all required maintenance before operating unit Service the unit in accordance with the Lubrication and Routine Maintenance schedule Inspect all structural members including attachment for signs of damage Inspect unit for obvious damage vandalism and necessary maintenance Check for signs of fuel lubricant coolant and hydraulic leaks Open all access doors and look for loose fittings clamps components and attaching hardware Replace hydraulic lines that are cracked brittle cut or which show signs of leakage or abrasion Form No 20219 534D 9 534D 10 Owner Operator Manual Use extreme caution when checking items beyond your normal reach Use an approved safety ladder Before operating handler complete all required maintenance Replace or repair all damaged worn or missing components before starting or operating handler Failure to properly maintain handler could cause serious injury or death Use a piece of cardboard or paper to search for leaks DO NOT use bare hands If
43. e protection from falling objects A fully enclosed cab with windows and a lockable door is available as an option The top half of the cab door must be secured in the fully opened or closed position The bottom half of the cab door can be secured in the closed position only Be sure the door is fully secured when operating the handler The operator s seat is equipped with a seat belt and includes fore and aft adjustment to compensate for variations in operator size The adjustment release lock is located beneath front edge of seat Wear seat belt when operating machine An optional windshield wiper washer is available for use with enclosed cabs A control switch is located on the instrument panel A variable speed defroster fan is available for use with enclosed cabs An On Off control switch and speed control are located on the base of the fan A heater fan is available for use with units equipped with a heater An On Off switch is located on the dashboard Hot water to the heater can be controlled by a valve at the engine The operator s cab is an S A E FOPS ROPS structure Do not make any modification to this structure If damaged the cab cannot be repaired It must be replaced CONTROL AND INSTRUMENT IDENTIFICATION Figure 3 1 IL FE LEVEL INDICATOR STEERING WHEEL FORWARD REVERSE LEVER AUXILIARY ELECTRICS OPTIONAL SHUTDOWN OVERRIDE SWITCH HDEERE ENGINES ONLY ATTACHMENT TIL
44. ed operating procedures can help you avoid accidents Because some procedures may be new to even the experienced operator we require that this Manual be read understood and complied with by all who operate this machine Strict attention to and compliance with instructions provided in this Manual the GRADALL Material Handler Safety Manual as well as instructional decals and plates affixed to the machine will help prevent injuries to personnel and damage to the equipment The information provided herein is not intended to cover all situations it is impossible to anticipate and evaluate all possible applications and methods of operation for this equipment This Manual covers recommended operating procedures and basic maintenance checks and services for the Material Handler Detailed maintenance information is available in the appropriate Service Manual Any procedure not specifically recommended by GRADALL must be thoroughly evaluated from the standpoint of safety before it is placed in practice If you are not sure contact your GRADALL Material Handler Distributor before operating Use only GRADALL authorized parts The use of counterfeit parts may cause premature failure which could lead to injuries and or machine damage Do not modify this machine without written permission from GRADALL Use only genuine GRADALL replacement parts OTHER NOTICES GRADALL retains all proprietary rights to the information contained in this Manual G
45. em dampens rear axle oscillation whenever the boom is raised over 45 from level However the system never locks the rear axle and is not designed to increase lateral stability Raising the boom loaded unloaded when handler is leaning to one side could cause machine to tip over with little or no warning and cause serious injury or death Always move boom to carry position horizontal or below before leveling frame Attempting to level machine with boom raised could cause it to tip over 11 1 Leveling Procedure 1 5 6 Position machine in best location to lift or place load and apply parking brake Observe level indicator to determine whether machine must be leveled Note position of indicator for later realignment If necessary to level handler position boom in carry position and level machine with the lever Lift or place load as appropriate Retract and lower boom to carry position Realign frame to position noted in step 2 Frame Leveling Controls Figure 11 1 TILT FRAME TILT FRAME C TILT FRAME TO LEFT TO LEFT TO RIGHT TILT FRAME TO RIGHT OPTIONAL STANDARD Form No 20219 534D 9 534D 10 Owner Operator Manual If handler cannot be leveled using leveling system do not attempt to raise or place load Have surface leveled 12 0 OPERATING PROCEDURE amp TECHNIQUES Hydraulic Controls All boom and attachment movements are governed by hydraulic cont
46. ent Installation y 1 Retract Quick Switch attachment tilt 2 Align boom head pivot with recess lever forward to provide clearance in attachment Raise boom slightly Check to be sure lock pin is secured in to engage boom head pivot in out position with retainer pin recess 4 Remove retainer pin and pin in fully 3 Engage Quick Switch attachment tilt lever backward 6 If attachment is equipped swing saddles down and pin in place 5 Secure lock pin in locked position using retainer pin Attachment Operation Operation of the handler equipped with carriage fork combination is covered in the GRADALL Material Handler Safety Manual and this Manual Operation of the handler when equipped with other approved attachments is covered in this section or in separate instructions furnished with the attachment Any separate instructions must be kept in Manual Holder in cab with this Owner Operator Manual Operate a handler equipped with an attachment as a partially loaded handler Pay special attention to capacity and range limits for the handler attachment combination Practice operation of handler and attachment in a safe open area not hazardous to yourself other persons equipment or property Become thoroughly familiar with response of handler and attachment to controls before operating in a work situation Always consider terrain between present location of load and delivery point Never attempt to transp
47. establish range and capacity limitations for will fit homemade altered or other non approved attachments e An overextended or overloaded handler can tip over with little or no warning and cause serious injury or death to the operator and or those working near the handler e GRADALL cannot assure the ability of a non approved attachment to perform its intended function safely e Non approved attachments may cause structural or other damage to the handler Such damage could cause dangerous operating conditions resulting in serious injury or death Carriage Fork Capacities The standard carriage fork capacity chart located on the dashboard indicates maximum reach and load capacities for handlers equipped with an approved carriage fork combination These limitations apply to standard GRADALL approved carriage fork combinations except as stated on the capacity chart Non standard carriage fork combinations greater or lesser capacity may be furnished by GRADALL at customer s request or may be available for installation because they were furnished for a different application If a carriage fork combination of lesser capacity is used the overall machine capacity is reduced to the capacity stamped on the carriage or forks whichever is less If a carriage fork combination of greater capacity is used the overall machine capacity may be reduced because of additional attachment weight and or other considerations Contact your local GRA
48. hart to the part number stamped on the Identification Plate The Machine Serial Number Plate is mounted inside the cab and lists all standard attachments that may be used with the machine by part number at the time it was shipped from the factory Be aware that a specific Capacity Chart must not only match the attachment but also the machine model The boom angle can be determined by looking at the angle indicator mounted on the side of the boom See figure 12 4 The boom extension can be determined by looking at the second boom section As the second boom section slides out of the main boom numbers are revealed starting with 1 Each number represents approximately 5 feet of total boom extension See figure 12 4 It is important to remember that these numbers are designed to be read from the operator s seat only How to read a Capacity Chart When reading the capacity chart you must check to be sure the correct model number is listed See figure 12 5 The next thing to look for is that the part number of your attachment is listed under the Use With section Identify and find the amount of boom extension required along with the angle of the boom Trace the boom extension arc down until it intersects with the appropriate boom angle If the intersection of the boom extension arc and the boom angle line occur within a weight region the value within that region is the maximum capacity for that particular lift If the intersection occurs on a
49. ide of differential Parking brake should be released TO RESTORE PARKING BRAKE 1 Make certain engine is stopped and all wheels are blocked 2 Loosen each release screw only 1 4 turn at a time in sequence until each screw has lost contact with guide pin Then remove release screws 3 Install previously removed spacer over bolt and install release screws and tighten 4 Repeat procedure on other side of differential Parking brake should be restored to operation C e SY UT 16 2 CARRARO AXLE 1 If possible position unit on level ground lower attachment to approximately one foot from ground move forward reverse lever to Neutral apply parking brake and stop engine 2 Block all wheels to prevent inadvertent movement Figure 16 3 RELEASE SCREW 12 o clock position FRONT OF MACHINE RELEASE SCREW 4 o clock position RELEASE SCREW 8 o clock position 3 Working one side at a time remove three plugs from differential housing located at 12 o clock 4 o clock and 8 o clock Put plugs aside 4 Tighten each release screw revealed by the plugs lightly until some resistance is felt 5 Working carefully tighten each release screw only 1 2 turn 1809 at a time in sequence until all three screws have been turned approximately five full turns Larger turns could cause components to bind and cause brake failure 6 Repeat this procedure on other side of differential Parking brake should be
50. ken This symbol indicates a hazard which may result in injury or damage to equipment or property if proper precautions are not taken Operator must be seated with seat belt fastened forward reverse lever in Neutral position parking brake applied and all hydraulic controls in Neutral before starting engine 1 1 Keep all windows and mirror s clean Adjust mirror s as required for maximum visibility before and during operation Never permit diesel engine to run out of fuel Doing so can cause severe engine damage DO NOT burn or drill holes in forks Modifying any part of machine or attachment may affect machine capacity and or stability Keep head arms hands legs and all other body parts inside the operator s cab at all times DO NOT approach power lines overhead or underground cables or other power sources with any part of your material handler or load unless all local state provincial and federal regulations have been met and the appropriate utility company has been contacted to de energize the lines Whenever leaving the cab perform standard shut down procedure Standard Shut Down Procedure Position the handler in a safe location apply parking brake lower forks to ground move all controls to Neutral allow engine to run at low idle for 3 to 5 minutes Stop engine and remove ignition key Block wheels Pinch Points Stay clear of pinch points and rotating parts on the material handler Getting caught i
51. ket with boom extended could damage structural members or extension chains cables e Avoid shock loads drive into stockpile smoothly to load bucket Do not use bucket as a lever to pry heavy material Excessive prying forces could damage the bucket Do not use bucket for back dragging This could cause severe damage to Quick Switch fittings A WARNING Observe all precautions and load capacity limits listed previously when handling loads with light material bucket 13 3 Operation e Raise or lower boom to appropriate height for loading material from stockpile e Align handler with face of stockpile and drive slowly and smoothly into pile to load bucket Do not corner load bucket e Tilt bucket up far enough to retain load and back away from pile e Lower bucket to carry position 4 feet 1 2m or less above ground and travel carefully to unloading point Turn bucket down to dump load Mast 6 1 8m with 4 1 2m or 6 1 8m carriage Capacity Maximum lift capacity indicated on attachment serial number plate applies only to certain areas within boom extension elevation pattern of handler mast combination A separate capacity chart must be used for handlers equipped with mast Study and understand this chart before attempting to handle a load with mast attachment Attachment Tilt Controls Figure 13 3 C LOWER The carriage tilt cylinder is used to tilt the FORKS mast and the carriage tilt lever contr
52. l electrical functions Level Indicator This bubble level indicator enables the operator to determine the left to right level condition of the handler Lights Switch optional This switch controls optional lighting which may be provided with the handler Machine Level Lever This lever controls the relationship of the handler frame to the front axle Push the lever forward to tilt frame to left pull lever back to tilt frame to right Parking Brake Switch This switch controls the application and release of the parking brake Form No 20219 534D 9 534D 10 Owner Operator Manual A brief description of controls and instruments is provided here as a convenience for the operator These descriptions DO NOT provide complete operation instructions Read amp understand this Manual and the GRADALL Material Handler Safety Manual 3 2 Parking Brake Indicator Light Glows red to indicate brake is applied Rotating Beacon Switch optional This switch controls operation of rotating beacon Seat Lock Release Lever This lever unlocks and locks seat position adjustment Service Brake Inching Travel Pedal This pedal operates the service brakes on the front axle It also permits slow travel speed while engine speed is kept high for other handler functions The further the pedal is depressed the slower the travel speed Full depression of pedal causes full service brake application Shutdown Override Switch Deere Engines Only
53. l instructions for lever handler movements Auxiliary Light Switch optional This switch turns auxiliary lights on and off Boom Control Joystick This joystick controls boom elevation and extension Pull joystick back to raise boom push joystick forward to lower boom Move joystick to right to extend boom move to left to retract boom Speed of boom movement is proportional to joystick actuation and engine RPM Check Engine Light Deere Engines Only Glows red for 30 seconds before engine shuts down when a Shutdown fault is detected Engine Coolant Temperature Gauge This gauge displays engine coolant temperature Engine Oil Pressure Gauge This gauge displays engine oil pressure Forward Reverse Lever This lever engages forward or reverse travel Lift amp push lever fully forward for forward travel Lift amp pull lever fully backward for reverse travel Move lever to centered position for Neutral Fuel Gauge This gauge displays level of fuel in fuel tank Heater Fan Switch optional This switch turns heater fan on and off Horn Button Depress button to sound horn Hourmeter This meter indicates total time of engine operation in hours and tenths of hours Ignition Switch This switch is actuated by a key In ACC or RUN position voltage is available for all electrical functions Full clockwise rotation to START engages starter motor Counter clockwise rotation to OFF stops engine and removes voltage from al
54. n a pinch point or a moving part can cause serious injury or death Before performing any maintenance on machine follow the STANDARD SHUT DOWN PROCEDURE 5 Rear Steering Axle Stabilizers D10 only Carriage Forks Form No 20219 534D 9 534D 10 Owner Operator Manual Contact The Gradall Company prior to welding on machine BATTERIES AND RELATED PARTS CONTAIN LEAD WASH HANDS AFTER HANDLING WARING Setters posta aed reinted socessores cerien med and noel oe peen ih dmn ies brews le ihe fta of Caif orr a to caute cance ane IO proCuct wo hae CALIEDHNIA PROP tS BATTERY WARNING Battery posts terminale and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm WASH HANDS AFTER HANDLING 2 0 DECALS INSIDE THE CAB O O CAPACITY CHARTS 9116 3184 REV A Located on dashboard P N 9116 3184 O 2 MODEL RATED CAPACITY zie IL 534D9 45 2 LOAD CENTER JV DEDUCT 300 LBS FROM ALL CAPACITIES WHEN MACHINE IS EQUIPPED WITH WINCH 4 36 USE WITH 9045 5051 48 CARRIAGE 9045 5052 66 CARRIAGE 9055 5008 72 CARRIAGE 9135 5004 WINCH 3 000 MAX CAPACITY 9134 3064 Located on dashboard P N 9134 3064 DO NOT ENGAGE PARK BRAKE
55. nd all manuals and instructional material listed on cover inside front cover and introduction page of this Manual before starting operating or performing maintenance procedures on this equipment Operators of this equipment must have successfully completed a training course in the safe operation of this type of material handling equipment Regardless of previous experience operating similar equipment the operator must be given sufficient opportunity to practice with the handler in a safe open area not hazardous to people or property to gain operating skills and the proper feel for controls and operating clearances required for safe efficient operation GRADALL Material Handlers are equipped with a right side rearview mirror This mirror is intended as an operator s aid and does not replace the requirement for line of sight Certain job site and machine conditions may require use of a signal person to help the operator when picking placing or transporting a load Never operate the handler until you know pick up point line of travel and landing point are clear Always be aware that objects in mirror are closer than they appear Safety Precautions Make sure all DANGER WARNING CAUTION and INSTRUCTIONAL DECALS are in place and can be read Clean or replace decals as required Ensure handler is on a firm level surface before lifting or placing load Have surface leveled if necessary Unit can tip over if load is raised with handler on
56. ng Mast attachment until you study and understand the Swing Mast Capacity Chart If your handler does not have a Swing Mast Capacity Chart ask your supervisor to get one before using the attachment Observe all precautions and load capacity limits when handling loads 13 8 Personnel Work Platform The material handler operator and personnel in the platform must read and understand the separate personnel work platform manual included with the attachment prior to using the platform Capacity The Gradall personnel work platform is designed to carry a maximum of 3 occupants The load includes personnel materials tools etc The maximum capacity of your work platform is based on specific model material handler work platform combination To determine maximum load capacity for given operating ranges consult the proper load capacity chart furnished with platform for the material handler and work platform in use If your handler is not equipped with the proper personnel work platform capacity chart get one before using the attachment Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See Page 13 1 Operation e Gradall Personnel Work Platforms are approved for use only on Gradall Material Handlers equipped with the proper platform capacity chart When lifting personnel use only a Gradall manufactured personnel work platform No other platform is approved for use on
57. ols AUXILIARY mast tilt The auxiliary control lever is used CONTROL LEVER to raise and lower the forks in the mast RAISE Pull lever back to raise forks push lever Fonks forward to lower forks Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See Page 13 1 2 Install mast on boom head 3 Connect auxiliary hydraulic hoses to mast cylinder Operation e Always level handler before raising the boom or the forks with or without a load e To travel with a load lower forks fully in mast and lower boom to position load 4 feet 1 2m or less above ground allowing for best visibility e Use mast as required to increase vertical reach of handler e Use a signal man to assist in positioning the load if necessary Swing Forks Capacity Maximum lift capacity for swing forks is shown on the attachment capacity chart However maximum lift capacity applies only to certain areas within boom extension elevation pattern of handler swing forks combination A separate capacity chart must be used for handlers equipped with swing forks Study and understand this chart before attempting to handle a load with swing forks attachment Form No 20219 534D 9 534D 10 Owner Operator Manual PRECAUTIONS e Read additional capacity information under Capacity heading e Because the mast increases lift height it is especially important to level the handler before lifting a load more than fo
58. om level ground in feet Elevation relates to dimension A shown on serial number plate inside cab front right side Boom Extension Numbers across bottom of sample chart and numbers parallel to boom represent boom reach as measured from front of front tires to extended position Number decals on boom relate directly to boom extension The largest number which can be read from operator s seat indicates total boom extension and must be matched with boom angle to determine load capacity Boom extension relates to dimension D shown on serial number plate Boom Angle Numbers shown at ends of angled lines represent angle of boom to horizontal as measured from horizontal Maximum angles are 4 below horizontal with boom fully lowered to 71 above horizontal with boom fully raised A boom angle indicator is located on left side of boom section 1 to show boom angle Be sure machine is level from front to rear or indicator will provide incorrect reading Load Center Loads shown on rated capacity chart are based on the load center being two feet 610mm above the horizontal surface and two feet 610mm forward of the vertical surface of the forks The load center of a load is the center of gravity of the load For regularly shaped loads of the same material such as a pallet of blocks the center of gravity can be located by measuring the load to find its center For irregular loads or loads of dissimilar materials keep the heaviest part
59. om up and down from the handler CONTROL LEVER boom head The carriage tilt lever controls RAISE truss boom tilt WINCH LOAD The auxiliary control lever is used when the truss boom is furnished with a winch Pull the lever back to raise winch load push the lever forward to lower winch load Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See Page 13 1 2 Install truss boom on boom head Operation e If truss boom winch is furnished connect auxiliary hydraulic hoses to winch e Approach truss or truss bundle with boom above and parallel to load e Position truss boom approximately parallel with main boom e Position truss boom winch hook as close as possible to balance point of load and secure load to boom using short slings or other rigging Be sure rigging will not allow load to slip in any direction PRECAUTIONS e Because the truss boom extends the reach of the handler maximum load capacity is reduced e Because of extended reach it is especially important to level the handler before lifting a load See Page 11 0 Travel with load and boom lowered to travel position 4 feet 1 2m or less above ground Always lower load to rest before leaving handler Do not handle a load with Truss Boom amp Truss Boom with Winch attachment until you study and understand the Truss Boom amp Truss Boom with Winch Capacity Chart If your handler does no
60. ort a load across terrain which could cause handler to tip over Form No 20219 534D 9 534D 10 Owner Operator Manual A WARNING This installation procedure is designed for one man operation If a helper is involved shut off the engine before proceeding to steps 4 5 and 6 Always be certain that carriage or attachment is properly positioned on boom head and is secured by lock pin and retainer pin Failure to ensure proper installation could permit carriage attachment load to disengage and cause serious injury or death 13 2 Fork Positioner Capacity Maximum load capacity for fork positioner carriage is the same as standard carriage without fork positioner Refer to Attachment Capacity Chart Capacity varies with boom extension and elevation positions Controls Figure 13 1 OPEN FORKS The auxiliary control lever is used to adjust fork position Pull lever back to close forks CONTROL LEVER CLOSE push lever forward to open forks FORKS Installation Procedure 1 Remove standard carriage fork combination or other attachment from boom head See Attachment Installation Page 13 1 2 Install carriage fork combination with positioner 3 Connect auxiliary hydraulic hoses to positioner cylinders Operation e Always adjust fork position before engaging load Moving forks after engaging load could cause load to fall from forks Light Material Bucket Capacity Maximum capacity of light material bu
61. parking on a slope cannot be avoided position the handler at a right angle across the slope straighten rear wheels and chock all wheels Parking procedure 1 2 3 Using service brake stop the handler in an appropriate parking area Move parking brake switch to On Shift forward reverse lever to Neutral Position attachment on ground Allow engine to cool at idle speed for 3 to 5 minutes stop engine and remove ignition key Chock wheels as an extra precaution against rolling Fill fuel tank to minimize condensation Lock cab and install protective covers if so equipped Disconnect batteries if unit is in an area where tampering is a risk 9 0 STEERING SYSTEM Rear wheel power steering is provided to reduce operator fatigue and to permit high maneuverability in close quarters It is imperative that the operator practice maneuvering the handler in a safe open area to become thoroughly familiar with steering response and clearance required for tail swing and load when turning A WARNING Be alert for any increase in effort needed to steer If any difference is noted notify maintenance personnel immediately If power assist feature should fail for any reason IT WOULD BECOME VERY DIFFICULT TO STEER For this reason it is extremely important that you NEVER TURN ENGINE OFF WHILE TRAVELING In the event power steering fails stop as soon as possible Do not drive handler until
62. pedal travel the less the pump flow the slower the travel The lower portion of pedal travel actuates the service brake The greater the pedal travel the stronger the brake application Travel flow is further reduced when brakes begin to apply See Figure 7 1 Four Wheel Drive When required by travel conditions rear wheel four wheel drive can be engaged by moving switch to Ax4 position Return unit to two wheel drive by moving switch to 4x2 position Four wheel drive can be engaged and disengaged while traveling When parking brake is applied four wheel drive is disabled Traction Lock Switch This switch pedal controls the traction lock valve which functions to restore tractive effort when a wheel spins in four wheel drive When switch pedal is depressed and held traction lock valve functions to cause delivery of full drive pressure to wheels of other axle regardless of low pressure at spinning wheel DO NOT engage traction lock function on improved surfaces Unit must be in four wheel drive to engage the traction lock function DO NOT engage traction lock function while wheels are turning Return engine to idle engage traction lock and increase RPM Disengage after traction resumes while in motion Form No 20219 534D 9 534D 10 Owner Operator Manual Bring handler to a complete stop before shifting forward reverse lever when carrying a load A sudden change in direction of travel could reduce stability and o
63. problem has been corrected 10 0 DRIVE TRAIN General The Material Handler covered by this Manual is equipped with hydrostatic drive From the operator s standpoint operation is similar to driving a vehicle equipped with an automatic transmission Major components of the system include a front drive axle with a differential and planetaries The differential receives torque from a variable displacement piston pump and a motor This combination of components eliminates the need for a conventional mechanical transmission and also provides inching travel These handlers also have piston motors to provide torque to rear wheel drive hubs as well as an electrically controlled valve which functions to restore tractive effort if conditions cause a wheel to spin Operation Normal Travel Direction of travel is selected by moving forward reverse lever forward for forward travel backward for reverse travel Move lever to center position for Neutral See Figure 3 1 for layout of controls If hydrostatic drive system senses increased travel load the system will compensate automatically by reducing travel speed to match load and engine RPM Inching Travel Inching travel is provided to permit slow travel speed while maintaining high engine speed for other handler functions The service brake inching travel pedal controls inching travel The upper portion of pedal travel actuates a valve which controls travel pump output The greater the
64. r cause load to shift or fall Practice inching braking in a safe open area until you are thoroughly familiar with response of machine to pedal travel Never disengage rear hubs except when activating tow bypass procedure 11 0 LEVELING THE HANDLER Leveling means positioning the handler so that it is level from side to side left to right A level indicator is located in the upper right corner of front window frame to permit operator to determine whether handler frame level See Figure 3 1 There are four very important things to remember about handler leveling 1 Never engage a load or lift a load more than four feet 1 2m above ground unless handler is level 2 A handler with the boom raised and or an attachment installed is a partially loaded handler 3 Once the handler frame is level and the handler has raised a load more than four feet 1 2m above ground it must not be moved from this position if such movement could change the level condition Do not use sway to level handler with load more than four feet 1 2m above ground 4 The combination of side tilt and load can cause the handler to tip over Two ways to level the handler The surface which will support the handler can be leveled This method must be chosen if it will be necessary to move the handler from its position after the load has been raised over four feet 1 2m from ground AND such movement could change the level condition Remember The
65. released TO RESTORE PARKING BRAKE 1 Make certain engine is stopped and all wheels are blocked 2 Loosen each release screw only 1 2 turn at a time in sequence until each screw has lost contact with guide pin Back out each screw until it bottoms out against the stop Then screw the bolts back in 1 4 turn 3 Install plugs over each release screw 4 Repeat procedure on other side of differential Parking brake should be restored to operation Form No 20219 534D 9 534D 10 Owner Operator Manual GRADALT 17 0 MAINTENANCE NOMENCLATURE Figure 17 1 STABILIZER FUEL HYDRAULIC CYLINDER TANK RESERVOIR CYLINDER Sar STABILIZER AIR STEERING OPERATOR S CLEANER AXLE CAB STABILIZER SHOE BOOM SECTION 1 BOOM SECTION 2 COMPENSATING BOOM SECTION 3 N CYLINDER BOOM HEAD O ma OPERATOR CAB SWAY CYLINDER ATTACHMENT TILT CYLINDER ONE EACH SIDE FRONT DRIVE AXLE LIFT PLANETARY STABILIZER HIDDEN CYLINDER HUB NOTE Stabilizers are standard equipment on all 534D 10 Materi
66. rm extended RAISE BOOM With either arm ex LOWER BOOM With either arm downward move arms back and laterally hand open downward tended horizontally fingers closed extended horizontally fingers move arm back and forth point thumb upward closed point thumb downward EXTEND TELESCOPIC BOOM With RETRACT TELESCOPIC BOOM With TILT FORKS UP With one arm held TILT FORKS DOWN With one arm both hands clenched point thumbs both hands clenched point thumbs at side extend other arm upward held at side extend other arm down outward inward at about 45 ward at about 45 CLOSE BUCKET Hold one hand OPEN BUCKET Hold one hand closed and stationary Rotate other open and stationary Rotate other MOVE SLOWLY Place one hand hand in small vertical circle with hand in small vertical circle with motionless in front of hand giving THIS FAR TO GO With hands raised forefinger pointing horizontally at forefinger pointing horizontally at motion signal Raise load slowly is and open inward move hands closed hand open hand shown laterally indicating distance to go STOP ENGINE Draw thumb or forefinger across throat Form No 20219 534D 9 534D 10 Owner Operator Manual 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 CALIFORNIA Proposition 65 Warning
67. rols Rapid jerky operation of hydraulic controls will cause rapid jerky movement of the load Such movements can cause the load to shift or fall or may cause the machine to tip over Feathering Feathering is a control operation technique used for smooth operation To feather controls move control lever very slowly until function begins to move then gradually move lever further until function is moving at desired speed Gradually move lever toward Neutral as load approaches destination Continue to reduce load speed to bring load to a smooth stop Feathering effect can be increased by reducing engine speed at beginning and near end of load movement Boom Control Joystick The boom control joystick can be positioned to activate individual boom movements or combinations of boom movements as illustrated Figure 12 1 LOWER LOWER amp BOOM LOWER amp BOOM p BOOM RETRACT EXTEND FRONT OF BOOM BOOM MACHINE RAISE amp gt YY RAISE amp RETRACT EXTEND BOOM RAISE BOOM BOOM With boom raised above horizontal forks can be inserted under a load by moving boom control joystick forward and to the right until forks move forward horizontally With boom raised above horizontal forks can be removed from a load by moving boom control joystick back and to the left until forks move rearward horizontally With boom lowered below horizontal forks can be inserted under a load by moving boom control joystick back and to the right until fork
68. rottle until engine coolant temperature reaches operating range Cold Weather Starting Aids In cold weather situations a supplemental starting aid may be required Gradall approved starting aids employ ether If your handler is equipped with an ether starting aid the following applies Cummins Engine e Hold switch on for 3 seconds to fill valve e Release switch to discharge ether while cranking engine e As engine starts use additional ether as required to keep engine running Deere Engine e Ether application is triggered by temperature gauge located on engine e At start up temperature gauge on engine will detect if ether is needed Follow normal start up procedure shown above e Ether is employed and additional will be released if needed to keep engine running e A second battery is added for additional cold cranking capacity Battery Boosted Starting If you ever have to battery boost start jump start your handler proceed as follows e Never allow vehicles to touch Connect the positive jumper cable to positive post of discharged battery e Connect opposite end of positive jumper cable to positive post of booster battery e Connect the negative jumper cable to negative post on booster battery Connect opposite end of negative jumper cable to ground point on machine away from discharged battery e Follow standard starting procedures e Remove cables in reverse order after machine
69. rvice be certain to return relief valve cartridges to original position and re engage rear drive hubs Form No 20219 534D 9 534D 10 Owner Operator Manual Towing handler with all wheels on ground for more than 200 yards 182m could cause serious damage to hydraulic drive components A CAUTION Do not operate hydrostatic drive system with rear hubs disengaged as the hydraulic rear drive motors may be severely damaged NOTE Forward relief valve is located on bottom of pump case directly below reverse relief valve 16 1 TO RELEASE PARKING BRAKE MERITOR AXLE 1 Position unit on level ground lower attachment to approximately one foot 3m from ground move forward reverse lever to Neutral apply parking brake and stop engine 2 Block all wheels to prevent inadvertent movement Figure 16 2 GUIDE PIN RELEASE SCREW fe ITU SECTION A 3 Working one side at a time remove three release screws and spacers from side of differential housing located at 12 o clock 4 o clock and 8 o clock 4 Put spacers aside and install release screws Tighten each screw lightly until it just makes contact with guide pin 5 Working carefully tighten each release screw only 1 4 turn 909 at a time in sequence until all three screws have been turned one full turn 360 approximately 50 ft lb 67n m Larger turns could cause components to bind and cause brake failure 6 Repeat this procedure on other s
70. s move forward horizontally With boom lowered below horizontal forks can be removed from a load by moving boom control joystick forward and to the left until forks move rearward horizontally The closer the boom to horizontal the less boom raise lower movement required for inserting and removing forks Carriage Tilt Controls Figure 12 2 TILT TILT TET Hr FORKS FORKS FORKS FORKS DOWN UP DOWN DOWN TILT TILT FORKS FORKS UP UP STANDARD OPTIONAL OPTIONAL GRYN YALE NOTE Much of the material in this section may be new to even the experienced operator Do not permit lift cylinders to hit the end of their stroke The jolt could topple loads causing a hazard to personnel and equipment nearby 12 1 Rated Capacity Chart The rated capacity chart located on dashboard indicates maximum load capacities for handlers equipped with GRADALL furnished carriage fork combination These capacities apply to standard carriage fork combinations except as stated on the capacity chart Figure 12 3 O MODEL MODEL 53409 45 T 53409 45 2007185 200185 1900185 i 3 1600 LBS Elevation Numbers at left side of sample chart represent elevation to top of horizontal fork as measured fr
71. se the swing forks can swing the load to the side it is especially important that the handler be level when handling a load more than four feet 1 2m above ground See Page 11 0 PRECAUTIONS e Level handler before tilting carriage to engage load e Always level handler before lifting a load more than four feet 1 2m above ground See Page 11 0 Do not handle a load with Slope Piler Carriage attachment until you study and understand the Slope Piler Carriage Capacity Chart If your handler does not have a Slope Piler Carriage Capacity Chart ask your supervisor to get one before using the attachment 13 5 e Tilt carriage to left or right to align forks with load and engage load e Raise load slightly and then level carriage e Travel with load lowered to travel position 4 feet 1 2m or less above ground Boom Head Mounted Winch Capacity The boom head mounted winch maximum load capacity is shown on the standard carriage capacity chart However maximum capacity may be used only in areas where it does not exceed capacities shown on standard carriage fork capacity chart located on dashboard Also note that maximum winch capacity is less than carriage fork maximum capacity Capacity rating is based on load being lifted and suspended vertically from the boom and with no load on forks Observe the following Special Precautions e Never drag the load lift vertically e Use tag line to guide and steady a suspended
72. supporting surface must be large enough smooth enough and firm enough to keep the handler level when it is moved from its position The handler may be leveled by means of the frame leveling system This method may be chosen when it will not be necessary to move the handler from its position after the load has been raised above four feet 1 2m from ground OR when such movement will not change the level condition of the handler Always determine best position for handler to raise load from its present location and also to position load at its destination THEN determine which method of leveling will be required at each location FINALLY consider terrain between present location of load and its destination Never attempt to transport a load across terrain which could cause handler to tip over Leveling Handler Frame The handler is designed to permit tilting main frame 8 to left or right to compensate for uneven ground conditions The rear axle pivots at the midpoint of the main frame to help ensure that all wheels will remain in contact with the ground A hydraulic cylinder provides a rigid connection between front axle and main frame to help ensure a solid work platform and to tilt main frame to left or right Optional rear axle stabilization is available for Material Handlers covered by this manual This system includes a hydraulic cylinder attached between the frame and the rear axle as well as flow restricting valving This syst
73. switch located on the dashboard With the engine running and the parking brake switch Off parking brakes are disengaged Moving the switch to On releases hydraulic pressure to apply the parking brakes With switch in ON position four wheel drive is disabled Form No 20219 534D 9 534D 10 Owner Operator Manual Practice inching braking in a safe open area until you are thoroughly familiar with handler response If power assist feature should fail for any reason it would require greater effort to apply service brake It is extremely important that you never stop the engine while traveling If power assist fails stop as soon as possible Do not drive the handler until problem has been corrected Always move parking brake switch to On position before leaving cab Never stop engine while traveling Parking brake will be fully applied and unit could stop abruptly A sudden stop could cause load loss NOTE In the event of engine or hydraulic failure parking brakes can be released for towing See To Release Parking Brake page 16 1 8 0 PARKING THE HANDLER Precautions Avoid parking on slopes or near an excavation Park on level ground and chock wheels Avoid parking on roads or highways If it cannot be avoided be sure to display warning flags during day and flares or flashing lights at night Position boom head or attachment on ground never leave machine with boom in air If
74. t have a Truss Boom amp Truss Boom with Winch Capacity Chart ask your supervisor to get one before using the attachment A side load or a swinging load could cause the handler to tip over and or damage the boom 13 7 e Open clamps at heel of truss boom far enough to clear load and tilt truss boom up until truss bundle contacts heel of truss boom e Close clamps to hold load lightly and secure clamps e Transport load to delivery site and attach tag lines if load will be freely suspended Swing Mast Capacity Maximum lift capacity is shown on attachment serial number plate However maximum lift capacity applies only to certain areas within boom extension elevation pattern of handler swing mast combination A separate capacity chart must be used for handlers equipped with mast Study and understand this chart before attempting to handle a load with swing mast attachment Controls Figure 13 8 SIDE SHIFT The carriage tilt cylinder is used to tilt the mast and the carriage Tilt lever controls mast tilt SWING MAST e Press right switch up to SIDE SHIFT to activate side shift function Move auxiliary hydraulic lever in appropriate direction e Press left switch down to SWING to activate swing function Move auxiliary lever in appropriate direction e Press right switch down to MAST to activate mast function Move auxiliary lever in appropriate direction Installation Procedure 1 Remove carri
75. t in positioning the load if necessary Slope Piler Carriage Capacity Maximum lift capacity for the slope piler carriage is shown on the attachment serial number plate However maximum lift capacity applies only to certain areas within boom extension elevation pattern of handler slope piler carriage combination A separate capacity chart must be used for handlers equipped with slope piler carriage Study and understand this chart before attempting to handle a load with slope piler carriage Attachment Tilt Controls Figure 13 5 TILT C COUNTER CLOCKWISE carriage tilt lever controls carriage tilt AUXILIARY m CONTROL The auxiliary control lever is used to tilt LEVER TILT slope piler carriage Push lever forward to CLOCKWISE tilt carriage counter clockwise pull lever back to tilt clockwise Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See Page 13 1 2 Install slope piler carriage on boom head Operation Connect auxiliary hydraulic hoses to slope piler carriage attachment Approach load with forks centered on load and stop handler e Level handler before tilting carriage to engage load PRECAUTIONS Read and understand additional capacity information under Capacity heading e Always level forks horizontally before swinging load to side Swinging unleveled forks may result in load slipping from forks e Becau
76. tor Qualifications Operators of the material handler must be in good physical and mental condition have normal reflexes and reaction time good vision and depth perception and normal hearing He must not be using medication which could impair abilities nor be under the influence of alcohol or any other intoxicant during the work shift The operator should possess a valid applicable driver s license and must have completed a training course in the safe operation of this type of material handling equipment In addition the operator must read view understand and comply with instructions contained in the following material furnished with the material handler e This Owner Operator Manual GRADALL Material Handler Safety Manual All warning and instructional decals and plates e Any optional equipment instructions furnished The operator must also read understand and comply with all applicable Employer Industry and Governmental rules standards and regulations Orientation When used to describe the location of components in the material handler the directions front rear right and left relate to the orientation of a person sitting in the operator s seat See Figure I 1 Related Manuals amp Decals Separate publications are furnished with the material handler to provide information concerning safety replacement parts maintenance procedures theory of operation and vendor components Replacement manuals decals
77. ur feet 1 2m above ground See Page 11 0 Do not handle a load with Mast attachment until you study and understand the Mast Capacity Chart If your handler does not have a Mast Capacity Chart ask your supervisor to get one before using the attachment Do not handle a load with Swing Forks attachment until you study and understand the Swing Forks Capacity Chart If your handler does not have a Swing Forks Capacity Chart ask your supervisor to get one before using the attachment 13 4 Attachment Tilt Controls Figure 13 4 gt SWING carriage tilt cylinder is used to tilt the LEFT swing forks up and down and the carriage tilt lever controls fork tilt AUXILIARY CONTROL LEVER SWING The auxiliary control lever is used to swing RIGHT the forks to the left and right Pull lever back to swing forks right push lever forward to swing forks left Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See Page 13 1 2 Install swing forks attachment on boom head 3 Connect auxiliary hydraulic hoses to swing forks attachment Operation e Always position forks straight ahead before engaging load e To travel with load keep forks in straight ahead position and lower load to 4 feet 1 2m or less above ground allowing for best visibility e Inspect supporting surface at delivery point and have it leveled if necessary e Use a signal man to assis
78. vailable Then select the appropriate method The ability to steer the handler increases the safety of moving the unit in some situations The steering system permits manual steering if engine or power assist feature fails Remember e Although manual steering is possible without power assist steering will be slow and will require much greater force MOVING SHORT DISTANCES If it is only necessary to move handler a short distance less than 100 feet 30m it is permissible to use a vehicle of sufficient capacity to tow the unit with no previous preparation Drive wheels will not roll If the unit must be moved more than 100 feet 30m but less than 200 yards 182m it is permissible to use a vehicle of sufficient capacity to tow unit after you e Activate Tow Bypass See below e Release parking brake See Page 16 1 MOVING LONGER DISTANCES If the handler must be moved more than 200 yards 182m it must be loaded on to a trailer of sufficient capacity TO ACTIVATE TOW BYPASS Figure 16 1 REVERSE RELIEF VALVE SMALL HEX LARGE HEX 1 Shut down machine and block wheels 2 Mark position of relief valve cartridge small hex 3 Hold large hex to prevent movement and loosen reverse relief valve cartridge small hex two full turns 4 Repeat steps 2 and 3 for forward relief valve Front axle drive is now bypassed 5 Disengage rear drive hubs Fairfield hubs do not disengage 6 Before returning machine to se
79. wer load to rest before leaving handler Do not handle a load with Boom Head Mounted Winch attachment until you study and understand the Boom Head Mounted Winch Capacity Chart carefully If your handler does not have a Boom Head Mounted Winch Capacity Chart ask your supervisor to get one before using the attachment 13 6 Truss Boom amp Truss Boom with Winch Capacity Maximum capacity for the truss boom with or without winch is shown on attachment serial number plate However maximum lift capacity applies only to certain areas within boom extension elevation pattern of handler truss boom combination A separate capacity chart must be used for handlers equipped with truss boom Study and understand this chart before attempting to handle a load with truss boom Observe the following Special Precautions e Never drag the load lift vertically e Use tag line to guide and steady a suspended load Tag lines must be long enough to keep helpers clear of load and handler e Beware of wind Wind can cause a suspended load to swing and cause dangerous side loads even with tag lines e Start travel turn and stop slowly to prevent load from swinging e Weight of all rigging slings etc must be included as part of load Do not attempt to use handler frame leveling to compensate for load swing Attachment Tilt Controls Figure 13 7 LOWER WINCH LOAD The carriage tilt cylinder is used to tilt the AUXILIARY truss bo
80. y incompletely burned fuel If the engine is not being used turn it off Stopping the Engine To stop engine perform standard shut down procedure e Operate engine at low idle for 3 to 5 minutes before turning it off This allows engine coolant and lubricating oil to carry excessive heat away from critical engine areas including turbocharger e Do not gun engine before shut down This practice causes incompletely burned fuel to remove oil film from cylinder walls and dilute lubricant in crankcase John Deere Engine Shut Down Protection Feature The feature monitors coolant temperature oil pressure and charge air temperature If any of the listed items cause a fault in the system the check engine light will illuminate and the engine will shut down after 30 seconds Within that 30 second period lower the boom and apply parking brake Report condition to your supervisor or maintenance personnel GRADALT A CAUTION Always keep engine cover closed while engine is running NOTE In the event of needing to delay a shutdown See Shutdown Override Switch Page 3 2 NOTE In the event of engine or hydraulic failure parking brakes can be released for towing See To Release Parking Brake Page 16 1 7 0 BRAKE SYSTEM General The brake system includes a service brake and a parking brake Service and parking brakes are applied through wet disc brake packs located within axle housing Because service braking and

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