Home

g6-42p material handler owner/operator manual

1. 2 1 INSIDE THE GRADALLIS A REGISTERED TRADEMARK FOR HYDRAULIC EQUIPMENT BUILT BY THE GRADALL MANUFACTURED IN THE USA MATERIAL HANDLER 406 MILL AVE SW NEW PHILADELPHIA OHIO 44863 MODEL G6 42P MACHINE SERIAL NO ENGINE SERIAL NO WEIGHT 355i 19 640 LBS AS RELEASED FROM FACTORY THIS TRUCK MEETS THE DESIGN SPECIFICATIONS 0 Sie ATTACHMENT 4F CARRIAGE PIN 91405043 TZ CARRIAGE PIN 9140 5045 48 SLOPE PILER PIN 9140 5101 72 SLOPE PILER PIN 9140 5079 WEIGHTS ARE BASED ON USING 2 X 4 X 48 FORKS APPROX 2688 PER PAIR BUCKET DIMENSIONS A amp D REFER BUCKET LIP HEIGHT TRUSS BOOM WINCH amp QUICK HOOK DIMENSIONS A amp D REFER TO HOOK CENTER 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 9141 3009 Located on right cab wall P N 9141 3009 GRADALL HANDLER SERVICE INTERVALS SERVICE INSTRUCTIONS DAT T WEE EVERY ROY FOR G6 42P dorks Ronee soos rocotins EQUIVALENT DIESEL ENGINE SAE 1581 40 00 preset FUEL 2 insPecr CHANGE MOBIL424 4 WOBIL424
2. MOBIL424 ETHYLENE GLYCOL 1 9 GAL 7 2 LTR WATER ANTI FREEZE 19 GAL 72 LTR ANTL FREEZE 5 QT 47 LTR OF SUPPLIMENTAL COOLANT ADDITIVE SCA TIRES 12 PLY 85 PSI TIRES RADIAL 70 PSI CYLINDER FITTINGS EACH END REAR AXLE 12 FITTINGS FRONT AXLE PIVOT 2 FITTINGS ALL BEARINGS PADS FRONT BOTTOM BEARING PADS BOOM PIVOT 2 FITTING HEAD PIN 2 FITTINGS QUICK SWITCH 1 FITTING RETRACT amp EXTEND CHAIN 1 4 1 ANSTIKTETRMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY STKTETRMOLY ANSTIKTETRMOLY SEE OPERATOR amp MAINTENANCE MANUAL RETRACT amp EXTEND CHAIN SHEAVES enEnsE THIS CHART MUST BE USED IN CONJUNCTION WITH SERVICE MANUAL AND RECOMMENDED PROCEDUI CHECK INDICATOR ON HYDRAULIC FILTER CHANGE FILTER IF NEEDLE IS IN RED FULL THROTTLE AND AT OPERATING TEMPERATURE CHECK AIR CLEANER RESTRICTION INDICATOR CLEAN OR CHANGE PRIMARY FILTER IF NECESSARY SAFETY ELEMENT TO BE CHANGED EVERY 3RD CHANGE OF PRIMARY FILTER ELEMENT CONSULT DEALER FOR RECOMMENDATIONS AT EXTREME TEMPERATURES DAILY SERVICE MAY BE REQUIRED FOR OPTIMUM LIFE DEPENDING UPON APPLICATION SEVERITY IF COOLANT IS ADDED TO RADIATOR ADD 3 SCA BY VOLUME IT IS RECOMMENDED THAT FILTER ELEMENTS FRONT AXLE LUBRICANT AND ENGINE OIL BE CHANGED AFTER FIRST 1
3. Located on right rear frame P N 9114 3280 Located on boom head P N 9055 3026 WARNING ATTACHMENT MUST BE SECURED TO MACHINE CHECK TO ASSURE QUICK SWITCH PLUNGER PIN IS FULLY ENGAGED AND LOCKED AFTER ATTACHMENT CHANGE IF PLUNGER PIN IS NOT FULLY ENGAGED AND LOCKED ATTACHMENT MAY FALL OFF CAUSING SERIOUS INJURY OR DEATH 9114 3290 Located on left side of boom P N 9100 3031 Located on left side of boom head P N 9114 3290 E GRADALL lt 9 GRADALL ATTACHMENT ATTACHMENT SERIAL NUMBER SERIAL NUMBER WEIGHT WEIGHT CAPACITY CAPACITY HYD PRESSURE HYD PRESSURE DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE THE CAPACITY OF FORKLIFT ATTACHMENT AND FORK PROPER GRADALL MATERIAL HANDLER PERSONNEL WORK COMBINATION MAY BE LESS THAN THE CAPACITY SHOWN PLATFORM CAPACITY CHART DISPLAYED IN CAB ON ATTACHMENT CONSULT FORKLIFT NAMEPLATE O AND ALSO INSURE FORKS ARE OF PROPER Located on personnel work platform Located on attachment P N 9055 3033 P N 9015 3001 WARNING WARNING READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM P H PO NT DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM KE EP OUT WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN
4. 5 Working carefully tighten each release screw only 1 4 turn 90 at a time in sequence until all three screws have been turned one full turn 3609 approximately 50 ft lb Larger turns could cause components to bind and cause brake failure 6 Repeat this procedure on other side 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 then install release screws and tighten 4 Repeat procedure on other side of differential Parking brake should be restored to operation GRADAC 11122 20 2 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 Chock all wheels to prevent inadvertent movement RELEASE i 5 SCREW Figure 20 3 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 Wor
5. Though no offense or discrimination is intended only the masculine pronouns will be used throughout the remainder of this Manual FRONT 3 T T 2 z 3 643 ToS NND 2 T REAR Figure I 1 Figure I 2 NOMENCLATURE ENGINE amp VALVE ENGINE HYDRAULIC HYDROSTATIC COMPARTMENT FILTERS TRANSMISSION CONTROL IMPLEMENT VALVES PUMP AIR MIRROR BATTERY CLEANER STEERING SWAY CYLINDER CYLINDER TIE DOWN LUGS 0 TIE DOWN LUGS STEERING FRONT DRIVE AXLE CYLINDER OPERATOR S STEERING CAB AXLE BOOM BOOM OPERATOR S HYDRAULIC RESERVOIR SECTION 2 SECTION 1 CAB BREATHER BOOM SECTION 3 HYDRAULIC RESERVOIR ATTACHMENT TILT CYLINDER COUNTER WEIGHT QUICKSWITCH LUG NUTS FUEL TANK PLANETARY HUB GRADALL 1 0 SAFETY Read and understand 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 meeting the OSHA Powered Industrial Truck Operator Training Requirements CFR 1910 178 for this type of material handling equipment Regardless of previous experience operating similar equipment the
6. 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 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 four 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 front view CRADALE Form No 20027 G6 42P Owner Operator Manual 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 16 0 LUBRICATION amp ROUTINE MAINTENANCE Lubrication Symbols ANTI FREEZE COOLANT CONDITIONER D
7. A WARNING Do not handle a load with Swing Forks attachment until you study amp 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 PRECAUTIONS Level handler before tilting carriage to engage load e Always level handler before lifting a load more than four feet above ground See Page 12 0 Do not handle a load with Slope Piler Carriage attachment until you study amp 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 14 5 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 A side load or a swinging load could cause the handler to tip over and or damage the 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 hel
8. Capacity Maximum capacity of light material bucket 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 14 2 LOWER LOWER RAISE LOWER BUCKET T BUCKET BUCKET BUCKET gt LIP LIP LIP RAISE BUCKET LIP RAISE BUCKET LIP OPTIONAL STANDARD OPTIONAL 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 14 1 2 Install light material bucket on boom head Operation e Raise or lower boom to appropriate height for loading material from stock pile PRECAUTIONS e Always adjust fork position before engaging load As with all other attachments handler must be level before handling a load more than four feet above ground level See Leveling The Handler Page 12 0 Observe all precautions and load capacity limits listed previously when handling loads with carriage fork positioner PRECAUTIONS Handler must be level before handling a load more than four feet above ground level See Page 12 0 e Retrac
9. in feet Elevation relates to dimension A shown on serial number plate inside operator s cab 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 9 below horizontal with boom fully lowered to 70 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 and two feet 610mm forward of surfaces of horizontal 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 of the load as close to the heel of the forks as
10. 9132 3030 WARNING FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF SERIOUS INJURY READ AND OBSERVE THE FOLLOWING 1 ONLY TRAINED AND AUTHORIZED PERSONNEL MAY 7 WHEN TRAVELING WITH LOAD FULLY RETRACT BOOM AND 15 BEFORE ADJUSTING OR SERVICING PLACE OPERATE THIS MACHINE PLACE FORKS IN CARRY POSITION APPROX 12 ABOVE FORWARD REVERSE LEVER IN NEUTRAL REST BOOM GROUND TILT CARRIAGE BACK SLIGHTLY CRADLE GROUND OR SUPPORT SET PARKING BRAKE SHUT OFF 2 BEFORE OPERATING READ AND UNDERSTAND ALL CAPACITY LOAD USE EXTREME CAUTION WHEN TURNING ENGINE AND CHOCK WHEELS CHARTS OPERATOR MANUALS AND SAFETY MANUALS IF MANUALS ARE NOT AVAILABLE CONSULT AN AUTHORIZED 8 ON INCLINES TRAVEL WITH LOAD UP GRADE 16 BEFORE LEAVING MACHINE UNATTENDED PLACE GRADALL DEALER UNDERSTAND ALL CONTROLS IN CAB AND FORWARD REVERSE LEVER IN NEUTRAL LOWER BOOM CHECK FOR PROPER OPERATION CLEAR LOOSE OBJECTS 9 DO NOT USE BOOM AS WALKWAY SET PARKING BRAKE AND SHUT OFF ENGINE CHOCK OFF MACHINE AND SOUND HORN BEFORE STARTING ENGINE 10 USE TWO HANDS WHEN CLIMBING ON MACHINE WHEELS IF MACHINE MUST PARK ON AN INCLINE 3 OPERATOR MUST BE SEATED WITH SEAT BELT FASTENED 41 USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK 17 LEVEL MACHINE BEFORE LIFTING ANY LOAD ABOVE 4 ASSURE FORWARD REVERSE LEVER IS IN NEUTRAL PARK PLATFORM FOR LIFTING PERSONNEL NO RIDERS ON MACHINE FEET IF EQUIPPED WITH FRAME LEVELING BRAKE AF OED OND ALEBE
11. 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 13 1 LOWER LOWER amp BOOM LOWER amp RETRACT EXTEND BOOM 2 BOOM RETRACT lt D gt EXTEND FRONT OF BOOM BOOM MACHINE RAISE amp lt e 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 forks move forward horizontally With boom lowered below horizontal forks can be removed from a load by moving boom control joystick forward and to the
12. The greater the pedal travel the stronger the brake application Travel flow is 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 the switch to 4x4 position Return unit to two wheel drive by moving the 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 tends to spin in four wheel drive When switch pedal is depressed and held traction lock valve forces oil to non spinning axle 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 if wheels are spinning at a high RPM Disengage after traction resumes while in motion C esM es LT 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 or 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 11 0 Checking 8 Adjusting Boom Boom Bearing Pads Boom bearing pads are to be adjusted for all boom sections This sh
13. employ ether If your handler is equipped with an optional ether starting aid the following applies Ether application is triggered by temperature gauge located on engine At start up temperature gauge on engine will detect if ether is needed Follow normal start up procedure shown above Ether is employed and additional will be released if needed to keep engine running 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 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 C esM es LT WARNING 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 CAUTION 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 rev
14. to cause cancer and reproductive harm C esM es LT 1 2 Pinch Points Stay clear of pinch points and rotating parts on the material handler Getting caught in a pinch point or a moving part can cause serious injury or death Before performing any maintenance on machine follow the STANDARD SHUT DOWN PROCEDURE on page 1 1 Carriage Forks Form No 20027 G6 42P Owner Operator Manual 2 0 DECALS INSIDE THE PACITY CHART GRADALL TRACTION LOCK CIFIC ATTACHMENT ON MACHINE GENERAL O O LOCKS FRONT amp REAR AXLES HYDRAULICALLY FOR INCREASED TRACTION DO NOT USE ON IMPROVED SURFACES MACHINE MUST BE IN WORK MODE DETERMINE BOOM MATCH WITH BOOM ANGLE TO FIGURES SHOWN ARE STACKING CAPAC RATED LIFTING CAPACITIES SHOWN ARE WITH LEVEL SURFACE WITH UNDAMAGED PROPERLY INFLATE MACHINE SPECIFICATIONS AND STABILITY ARE BASED ON RATED CAPACITIES AT SPECIFIC BOOM ANGLES AND BOOM LENGTHS IF SPECIFICATIONS ARE CRITICAL THE PROPOSED APPLICATION SHOULD BE DISCUSSED WITH YOUR DEALER 9140 3529 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 CAPACI
15. 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 transport a load across terrain which could cause handler to tip over Form No 20027 G6 42P Owner Operator Manual 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 would permit carriage attachment load to disengage and cause serious injury or death 14 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 gt OPEN FORKS CLOSE FORKS Controls Figure 14 1 The auxiliary control lever is used to adjust fork position Pull lever back to close forks push lever forward to open forks AUXILIARY CONTROL LEVER Installation Procedure 1 Remove standard carriage fork combination or otherattachment from boom head See Attachment Installation Page 14 1 2 Install carriage fork combination with positioner 3 Connect auxiliary hydraulic hoses to positioner cylinders Light Material Bucket
16. 00 HRS ON NEW OR REBUILT UNITS unii Located on right cab wall P N 9141 3012 Located on dash Starting S N 0160001286 P N 9141 3061 Form No 20027 G6 42P Owner Operator Manual SD 57201 GRADALL MATER MAX WEIGHT 2150 MEETS SAE J1040 MEETS ISO 3471 94 3 MEETS ANSI B56 6 8 16 P GRADALL 9114 3261 SERIAL Located on back wall behind operator s seat P N 9140 4289 enclosed cab P N 9140 4111 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 Y 000850 Located on left side front cab plate P N 9116 4094 FORWARD NEUTRALS REVERSE Located on forward reverse lever P N 9116 3028 A 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 w turbo option P N 9134 3016 2 2 OUTSIDE THE 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 medica
17. 6 42P Owner Operator Manual A WARNING PRECAUTIONS Maximum winch load capacity is reduced from normal carriage fork load rating e Always level handler before lifting a load See Page 12 0 Travel with load and boom lowered to travel position load approximately one foot above the ground Always lower load to rest before leaving handler Do not handle a load with Boom Head Mounted Winch attachment until you study amp understand the Boom Head Mounted Winch Capacity Chart If your handler does not have a Boom Head Mounted Winch Capacity Chart ask your supervisor to get one before using the attachment PRECAUTIONS 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 12 0 e Travel with load and boom lowered to travel position load approximately one foot above ground e Always lower load to rest before leaving handler 14 6 Truss Boom amp Truss Boom with Winch A side load or a swinging load could cause the handler to tip over and or damage the boom Observe the following Special Precautions Never drag the load lift vertically 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 sid
18. CAB WITH PERSONNEL IN DIRECT LINE OF SIGHT OPERATE CONTROLS LIGHTLY AND CAUTIOUSLY WHEN LIFTING PERSONNEL READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER S MANUAL BEFORE LIFTING PERSONNEL 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 REACHING INTO BOOM HOLES AND OTHER PINCH POINTS CAN CAUSE SERIOUS INJURY OR DEATH 9055 3027 REV A 8060 3037 Located on mudguard P N 9055 3027 Located on boom P N 8060 3037 3 0 OPERATOR S CAB OPERATOR S CAB The standard cab permits vision from all sides and includes an overhead guard to provide 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 and window are 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 on the side 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 instrumen
19. DRADEIC CONTROLS AREIN FORKS LOAD OR OTHER LIFTING ATTACHMENTS AT ANY LOAD 18 OPERATOR PROTECTION SUCH AS HARD HATS SAFETY NEUTRAL BEFORE IGNITION SWITCH IS TURNED TIME DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE GLASSES AND OR HEARING SHOULD BE PROPER GRADALL MATERIAL HANDLERIPERSONNEL WORK WORN WHEN JOB CONDITIONS WARRANT ALWAYS USE CHART IN BASE MACHINE WITHOUT PROPER CAPACITY PLATFORM CAPACITY CHART DISPLAYED IN THE CAB DO NOT SEAT BELT 4 DRIVE MACHINE WITH PERSONNEL IN PLATFORM 5 BEFORE MOVING BE SURE OF A CLEAR PATH AND SOUND 19 IMPROPER USE OF MACHINE COULD RESULT IN MACHINE HORN WATCH FOR PEDESTRIANS AND OBSTRUCTIONS 12 KEEP OTHERS AWAY TROM MACHINE WHILE OPERATING TIPPING OVER IF MACHINE STARTS TO TIP OVER DO CHECK OVERHEAD AND SIDE CLEARANCES ALWAYS LOOK DO NOT STAND UNDER BOOM OR LOAD NOT LEAVE OPERATORS SEAT LEAN AWAY FROM TIP amp IN DIRECTION TRAVEL 13 USE EXTREME CARE WHEN HANDLING LONG HIGH OR BRACE YOURSELF 6 START TURN AND BRAKE SMOOTHLY REDUCE TRAVEL WIDE LOADS DO NOT HANDLE UNSTABLE OR LOOSELY 20 KEEP MIRROR S CLEAN AND PROPERLY ADJUSTED SPEEDS FOR TURNS SLIPPERY OR UNEVEN SURFACES STACKED LOADS OBJECTS IN MIRROR ARE CLOSER THAN THEY APPEAR AVOID RENNES GVER LOOSE OBJEGTS ORHOLES INTHES 14 FORKS TO BE CENTERED UNDER LOAD AND SPACED APART ROADWAY SURFACE AS FAR AS POSSIBLE 9055 3028 REV A Located on right cab wall P N 9055 3028
20. G6 42P MATERIAL HANDLER OWNER OPERATOR MANUAL COVERING OPERATION amp PERIODIC MAINTENANCE r I n materi IMPORTANT Read and understand this Manual and the Gradall Material Handler Safety Manual before starting operating or performing maintenance procedures on this machine GRADAEL KEEP OPERATOR AND SAFETY MANUALS IN CAB A Jif Company COVERS MATERIAL HANDLER MODEL G6 42P JLG STARTING SERIAL NUMBERS P Form No 20027 0189001 THRU 0189345 Part No 9140 4003 amp 0160000230 THRU 0160004017 Revised 11 25 08 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 recommended 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 itis impossible to anticipate and evaluate all possible applications and methods of operation for this eq
21. IESEL FUEL ENGINE FUEL HYDRAULIC FLUID MOLY LUBE extreme pressure IMPORTANT NOTICE SYMBOLS FAILURE TO USE GRADALL Be certain to check extend chain Lube Fitting adjustment every 5 weeks or 250 Other Service HYDRAULIC FILTER ELEMENTS hours and adjust as required Chain Service Both Sides COULD VOID WARRANTY damage can occur if chain is not adjusted properly 24 25 26 27 28 12 15 29 13 17 31 35 18 36 43 37 42 39 40 20 34 32 33 14 41 38 10 LUBRICATION NOTICE 22 23 11 e After greasing machine cycle all functions several times to distribute lubricants Perform this maintenance procedure without attachment or forks installed Apply a 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 lint free cloth 16 1 Service intervals are based on machine usage of 1500 hours annually Use of your unit may vary significantly and you must adjust service frequency for your usage to obtai
22. ISCHARGED BATTERY FOLLOW STANDARD STARTING PROCEDURES REMOVE CABLES IN REVERSE ORDER AFTER MACHINE HAS STARTED 9114 3285 Located on engine cover P N 9114 3284 Located on engine cover P N 9114 3285 WARNING STAY CLEAR OF MOVING PARTS WHILE ENGINE IS RUNNING MOVING PARTS CAN CAUSE SERIOUS INJURY CAUTION COOLING SYSTEM IS PRESSURIZED REMOVE CAP SLOWLY HOT FLUID CAN f CAUSE BURNS Located on engine cover P N 9114 3281 Located on radiator P N 8060 3026 8060 3026 2 3 OUTSIDE THE 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 2080 3022 Located on mud guard P N 8060 3022 WARNING NEVER OPERATE MACHINE WITHOUT CONSULTING PROPER CAPACITY CHART FOR THE CARRIAGE FORK COMBINATION BEING USED 9132 3030 Located on mud guard P N 9132 3030 FULL ADD HYDRAULIC OIL LEVEL CHECK OIL LEVEL WITH HANDLER LEVEL AND ALL CYLINDERS RETRACTED 2 5 GALLON BETWEEN ADD AND FULL MARKS 9140 3569 Located on hydraulic reservoir P N 9140 3569 7733 3027 Located on left
23. Mntg Bolts Annually 1500 hrs 3 4 10 Steering Cylinder Rod to Knuckle Mntg Pin Bottom 6 Months 1000 hrs 1 1 4 12 Check torque at whichever interval occurs first CAUTION The preceeding bolt torque chart covering English and Metric fasteners are used by Gradall engineering Gradall ratings are for lubricated fasteners Do not exceed the allowable rating An over torqued bolt in most cases will fail as rapidly as an under torqued bolt Form No 20027 G6 42P Owner Operator Manual 19 0 OBTAINING HYDRAULIC OIL SAMPLE 8 9 Operate unit until hydraulic oil reaches normal operating temperature Apply parking brake lower boom to rest 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 located above implement pump 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
24. ON AND MAINTENANCE LOG 515 55 xen ute De RES inside back cover Ce esM es LT INTRODUCTION General This Manual provides important information regarding safe operating procedures and maintenance requirements for GRADALL G6 42P Material Handlers If you have any questions regarding the material handler contact your GRADALL Material Handler Distributor Operator 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 meeting the OSHA Powered Industrial Truck Operator Training Requirements CFR 1910 178 for 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 e GRADALL Material Handler Safety Manual e All instructional decals and plates Any optional equipment instructions furnished The operator must also read understand and comply with all applicable Employer Industry and Governmental rules standards and regul
25. TY CHART NUMBER PLATE Located above traction lock pedal P N 9140 3529 LEVEL GRADALL HANDLER BEFORE LIFTING ABOVE 4 FT sosis 9140 3618 Located on dashboard 1 P N 9140 3618 74 ENSE MODEL MODEL WERDE WHEN MACHINE S G6 42P G6 42P 1 48 4 T T T T T T 48 J Li HB 70 Bao 60 g amp 9150 3102 REV 5 8 4 a NZ 2 50 2 of 80 a 32 xy So 35 9 Located on right cab wall wt w EA P N 9150 3102 al NE Nee EIS NE i oA S VS D e 8 2 183 20 a tS z tapea Ek s 12 8 8 8 12 4 10 17 8 28 WARNING P e s H Ou 48 pev reor NEVER OPERATE MACHINE WITHOUT E M oL UD CN NEN CONSULTING PROPER CAPACITY CHART FOR THE USE WITH 9140 5101 48 USE WITH 9140 5043 48 CARRIA CARRIAGE FORK COMBINATION BEING USED 9140 5079 72 9140 5045 72 CARRIAGE SLOPE PILER CARRIAGE 9140 5024 WINCH 4 0001 MAX CAPACITY 9141 3011 9132 3030 IW A samson o BACK FRONT Located on dashboard Located on right cab wall P N 9141 3011 P N
26. al This system includes a hydraulic cylinder attached to the frame and the rear axle as well as flow restricting valving This system 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 12 1 Leveling Procedure 1 Position machine in best location to lift or place load and apply parking brake 2 Observe level indicator to determine whether machine must be leveled Note position of indicator for later realignment 3 If necessary to level handler position boom in carry position and level machine with the lever 4 Lift or place load as appropriate 5 Retract and lower boom to carry position 6 Realign frame to position noted in step 2 Form No 20027 G6 42P Owner Operator Manual WARNING If handler cannot be leveled using leveling system do not attempt to raise or place load Have surface leveled 13 0 OPERATING PROCEDURE amp TECHNIQUES Hydraulic Controls All boom and attachment movements are governed by hydraulic controls 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
27. ations Orientation When used to describe the location of components in the material handler the Hw 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 and instruction plates can be ordered from your GRADALL Material Handler Distributor Models Covered This Manual covers the G6 42P Material Handler This unit is equipped with a three section boom and four wheel drive Optional equipment available for use with this unit is described in appropriate sections of the 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 Nomenclature The illustrations on the next page include nomenclature applied to major components of the material handler Form No 20027 G6 42P Owner Operator Manual NOTE Material handler and handler are used interchangeably throughout this Manual NOTE
28. 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 Steering Wheel The steering wheel controls the angle of 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 Indicator light on switch glows amber to indicate four wheel drive is engaged When park brake is applied light will not glow OPTIONAL HEATER CONTROLS Figure 3 2 AIR VENT DEFROSTER FAN TEMPERATURE CONTROL BLOWER CONTROL ACCESS COVER HEATER VENT HEATER 2 Form No 20027 G6 42P Owner Operator Manual 4 0 CHECKS 8 SERVICES BEFORE STARTING ENGINE To be performed at the beginning of each work shift e If spark arrestors are required be sure they are in place and in good working order e Check to be certain that windows and mirror s are clean and undamaged Also make certain that mirror s are properly adjusted for o
29. cab wall P N 7733 3027 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 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 left cab wall P N 9114 3286 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 engine cover and boom head P N 9114 3282 Form No 20027 G6 42P Owner Operator Manual 2 4 OUTSIDE THE WARNING WARNING EXHAUST SYSTEMS CAN BE HOT KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT HOT EXHAUST COMPONENTS CAN CAUSE SEVERE BURNS 8114 5580 READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM ALL PERSONNEL IN PLATFORM MUST WEAR A FULL BODY HARNESS WITH LANYARD ATTACHED TO A DESIGNATED ANCHORAGE POINT READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER S MANUAL BEFORE OCCUPYING PERSONNEL WORK PLATFORM FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH 9055 3026 REV A
30. 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 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 carriage fork capacity as indicated on carriage fork serial number plate 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 GRADALL Distr
31. e 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 If power steering fails stop as soon as possible Do not drive handler until 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 Operation Normal Travel Direction of travel is selected by moving forward reverse lever forward for forward travel backward for reverse travel Lift and 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 pedal travel the less the pump flow the less the pump flow the slower the travel The lower portion of pedal travel actuates the service brake
32. e 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 14 7 LOWER WINCH The carriage tilt cylinder is used to tilt the AUXILIARY truss boom up and down from the handler CONTROL LEVER boom head The carriage tilt lever controls 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 14 1 2 Install truss boom on boom head 3 If truss boom winch is furnished connect auxiliary hydraulic hoses to winch Operation 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 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 Close clamps to hold load lightly and secure clamps e Transpor
33. ed 9134 3016 Decal added 9114 3290 Decal revised P N 9055 3027 revised Operators revised optional Cod weather Staring Nd revised steering system section revised General sein 2 removed pure 13 4 revised Load Center reves gee 7 revises Front and Rear nub Capacities Rear Hub Toraue Values added Fiexplate Mounting Bots Torque Values Traded mentor ae to ele of page O page for Form 20027 G6 42P Owner Operator Manual TABLE OF CONTENTS IMPORTANT SAFETY NOTICE inside front cover TABLE OF CONTENTS INTRODUCTION General Operator Qualifications Orientation Related Manuals amp Decals Serial Number Location NOMENCLATURE SAEETY qaa utn Fal A UA a RU UE 1 0 thru 1 2 TE 2 0 thru 2 4 Decals Inside Cab Decals Outside Cab OPERATORS ecran a aaa eara ari e ER REN RET RR COR RR T 3 0 thru 3 2 Cab Control amp Instrument Identification CHECKS amp SERVICES BEFORE STARTING ENGINE 4 0 WARM UP amp OPERATIONAL 5 0 ENGINE OPERATION 6 0 thru 6 1 Starting the Engine Cold Weather Starting Aids Battery Boosted Starting Normal Engine Operation Stopping the Engine BRAKE SYSTEM 2 vas PORE IER Ex EA E RR 7 0 General Inching Trave
34. erse 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 by 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 Do not gun engine before shut down This practice causes incompletely burned fuel to rem
35. forks in the mast Pull lever back to raise forks push lever forward to lower forks AUXILIARY CONTROL LEVER RAISE FORKS Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See Page 14 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 approximately one foot above ground Use mast as required to increase vertical reach of handler Use a signal person 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 Attachment Tilt Controls Figure 14 4 SWING gt LEFT The carriage tilt cylinder is used to tilt the swing forks up and down and the carriage AUXILIARY tilt lever controls fork tilt CONTROL LEVER SWING RIGHT The auxiliary control lever is used to swing the forks to the left and right Pull lever back to swing forks right push lever forward to s
36. from its position after the load has been raised over four feet from ground AND such movement could change the level condition Remember The 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 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 manu
37. ginning of each work shift The safety efficiency and service life of your handler will be increased by WARNING performing the operational checks listed below Items preceded by an asterisk are optional and may not be furnished on your machine for damage due to impact Before entering the operator s cab check 1 AirFilter Restriction Indicator If pop up indicator is red filter is clogged and element must be cleaned or changed and indicator reset 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 Must be audible from inside operators cab with engine running 10 All boom and attachment functions operate smoothly and correctly 11 Hydraulic Filter Condition Indicator observe engine coolant temperature A CAUTION 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 Continued operation with hydraulic lower forks fully shift forward reverse lever to Neutral position and fluid bypassing the filter may cause block wheels With engine running at f
38. hain lock nut and adjusting nut Tighten retract chain adjusting nut until proper distance between 2 and 35 boom sections and proper access hole alignment is obtained Torque lock nut to 100 lb ft Adjust extend chain per instructions above mo o For more detailed information including boom chain checks and adjustments see the appropriate Service Manual Form No 20027 G6 42P Owner Operator Manual 12 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 upper right corner of front window frame to permit operator to determine whether the handler frame is level There are four very important things to remember about handler leveling 1 Never engage a load or lift a load more than four feet 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 operator has raised a load more than four feet 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 above ground 4 The combination of side tilt and load could cause the handler to tip over 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
39. ibutor to determine capacity limitations Other Attachment Capacities Aserial 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 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 14 1 Attachment Installati
40. igure 14 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 carriage fork combination or other attachment from boom head See Page 14 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 approximately one foot above ground 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 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
41. int and have it leveled if necessary Use a signal person to assist 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 14 5 TILT gt COUNTER The carriage tilt lever controls carriage tilt CLOCK AUXILIARY WISE The auxiliary control lever is used to tilt slope carriage Push lever forward to tilt carriage counter clockwise pull lever WISE back to tilt clockwise Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See Page 14 1 2 Install slope piler carriage on boom head 3 Connect auxiliary hydraulic hoses to slope piler carriage attachment Operation e Approach load with forks centered on load and stop handler Level handler before tilting carriage to engage load Tilt carriage to left or right to align forks with load and engage load Raise load slightly and then level carriage Travel with load lowered to travel position load approximately one foot above ground C esM es LT
42. ke circuit 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 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 Practice inching braking 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 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 position before leaving cab Never stop engine while traveling all hydraulic pressure will be lost and parking brake will be fully applied causing unit to stop abruptly A sudden stop could cause load loss NOTE In the event of engine or hyd
43. king 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 released TO RESTORE PARKING BRAKE 1 Make certain engine is stopped and all wheels are chocked 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 20027 G6 42P Owner Operator Manual INSPECTION AND MAINTENANCE LOG This page is provided so you may record all inspections and maintenance on your machine Record the date hourmeter reading and a detailed description of the procedure in the comment area Record all information in the Owner Operator Manual stored in the operator s cab Hourmeter Reading Form No 20027 G6 42P Owner Operator Manual INSPECTION AND MAINTENANCE LOG Hourmeter Comments Reading 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 opera
44. l Service Brakes Parking Brakes PARKING THE HANDLER 8 0 STEERING SYSTEM i cora pn su xax vani ire hin re Fine ie e dE KENN 9 0 DRIVE TRAIN ced teak Rx sad de 0408 io da A 10 0 BOOM nanei E dx rana 11 0 LEVELING THE 12 0 thru 12 1 OPERATING PROCEDURE amp TECHNIQUES 13 0 thru 13 1 Hydraulic Controls Rated Capacity Chart AMACHMENTS 14 0 thru 14 7 Approved Attachments Non Approved Attachments Carriage Fork Capacities Other Attachment Capacities Attachment Installation Attachment Operation LOADING amp SECURING FOR TRANSPORT 15 0 LUBRICATION amp MAINTENANCE 16 0 thru 16 1 RECOMMENDED LUBRICANTS amp CAPACITIES 17 0 TORQUE CHART 4 5 5 cnni n I nach e RR RAP OE UE ened OE 18 0 OBTAINING HYDRAULIC OIL SAMPLE FOR ANALYSIS 19 0 MOVING HANDLER IN EMERGENCY 20 0 thru 20 2 Moving Short Distances Moving Longer Distances To Activate Tow Bypass To Release Parking Brake To Restore Parking Brake INSPECTI
45. l help Immediate surgery is required to remove oil Do not use finger or skin to check for leaks Lower load or relieve hydraulic pressure before loosening fittings Located on frame below engine cover 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 frame below engine cover P N 9114 3288 Located on hydraulic fill cap P N 9140 3573 WARNING LEAD ACID BATTERIES PRODUCE FLAMABLE AND EXPLOSIVE 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 9114 3284 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 D
46. left until forks move rearward horizontally The closer the boom is to horizontal the less boom raise lower movement required for inserting and removing forks Carriage Tilt Controls Figure 13 2 FORKS 28 FORKS FORKS FORKS DOWN DOWN UP DOWN TILT TILT FORKS FORKS UP UP OPTIONAL STANDARD OPTIONAL Ce eo es LT NOTE Much of the material in this section may be new to even the experienced operator Do not permit lift cylinder to hit the end of stroke The jolt could topple loads causing a hazard to personnel and equipment nearby 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 13 1 Rated Capacity Chart The rated capacity chart located on dashboard indicates maximum load capacities for handlers equipped with GRADALL furnished carriage fork or other attachment combinations These capacities apply to standard carriage fork and other attachment combinations except as stated on the capacity chart Figure 13 3 GRADALL CAPACITY BACK FRONT Elevation Numbers at left side of sample chart represent elevation to top of horizontal fork as measured from level ground
47. m fully three times and wipe excess lube from bearings HM 4 7 Carriage Tilt Cylinder Pivots HM 2 8 Boom Hoist Cylinder Pivots HM 2 9 Compensating Cylinder Pivots HM 2 10 Boom Head Carriage Pivot HM 2 11 Tires check for damage and proper inflation 1300 x 24 12 ply 70 psi 4 12 Radiator Fill Cap check level and refill as required 1 17 Fuel Filter Water Separator with Drain replace element 1 19 Quick Switch Latch HM 1 26 Leveling Cylinder Pivots HM 2 29 Battery check terminals 1 36 2 37 Steering Cylinder Rod Pivots HM 2 38 Steering Cylinder Barrel Pivots HM 2 39 Boom Pivots HM 2 40 Front Axle Pivots HM 2 42 Rear Axle Pivots HM 2 43 King Pins HM 4 At End of First 100 Hours Only 15 Special engine breakin oil drain amp refill replace filter EO 1 23 Planetary Drain Plugs drain while draining differential HF 2 25 Differential Drain Plug drain and refill HF 1 Check torque of all items listed in Torque Chart pg 18 0 DETAILED SERVICE INSTRUCTIONS ARE CONTAINED IN THE GRADALL SERVICE At End of First 30 Days Only 250 Hours Maximum Lubrication amp Maintenance 2 Boom Front Top and Side Slide Bearings extend boom fully and Lube all wear paths retract and extend boom fully three times and wipe excess lube from bearings HM 12 3 Boom Rear Slide Bearings lube paths HM 12 4 Boom Extend Chain check adjustment and adjust as required 2 6 Boom Fro
48. n fill to level wait 5 minutes and fill to level again item 24 is fill level plug HF 3 28 Front Axle Breather clean or replace 1 1500 Lubrication amp Maintenance include all previous periodic services 12 Engine Cooling System drain flush and refill on basis of period suggested by anti freeze manufacturer and add Liquid Coolant Additive CC AF 1 31 Hydraulic Return Filter replace filter element 1 32 Hydraulic system unless fluid is analyzed quarterly to determine degree of contamination reservoir must be drained and refilled on an annual basis HF 1 33 Hydraulic Reservoir Screen remove clean and install when hydraulic oil is drained 1 35 Hydraulic Suction Filter replace filter element 1 MANUAL FOR YOUR PARTICULAR MATERIAL HANDLER Form No 20027 G6 42P Owner Operator Manual 17 0 RECOMMENDED LUBRICANTS amp 5 APPLICATION SYMBOL LE re SPECIFICATION CAPACITY Boom Boom Cham CL CL chain lube lube All Year Aver 00 00 P N 1440 4751 1 Boom Bearing Paths Boom Bearing Paths HM extreme pres lube HM extreme pres lube pres ube All Year A Year Year 2 2 P N 1440 4595 P N 1440 4595 4595 Coolant Conditioner CC supplemental Year 0 5 m 0 48 L coolant additive Engine Engine Cooling System System anti freeze anti anti freeze Al Year Year V2 V2 Pe
49. n maximum service life Frequency headings in the following schedule indicate a calender limit and an operating hour limit Perform CAUTION service at whichever interval occurs first Daily or Shift 10 hour Maximum Lubrication amp Maintenance Lube No of Symbol Points Lube No of Symbol Points 5 Week or 250 Hour Lubrication amp Maintenance include all previous periodic services 13 Engine Crankcase Dipstick level handler and check level refill as required item 14 is filler cap EO 1 30 Fuel Filler Cap fill at end of work shift to minimize condensation DF 1 31 Hydraulic Return filter Condition Indicator check indicator with oil at normal operating temperature and engine running at full throttle replace filter element before by pass indication is reached or at least annually 1 34 Hydraulic Level Sight Gauge level handler retract all other cylinders and check sight gauge refill as required HF 1 35 Hydraulic Suction Filter replace filter element when return filter element is replaced 1 41 Air Cleaner Element Condition Indicator check for clogged condition red band showing and clean or replace element as required E 1 Weekly or 50 Hour Lubrication amp Maintenance include all previous periodic services 1 Extend Retract Chain Sheaves HM 3 6 Boom Bottom Front Slide Bearings extend boom fully and lube all wear paths retract and extend boo
50. nt bottom Slide Bearings to be performed by experienced maintenance person check for damage and excessive wear no wear permitted past bevel maximum clearance at top bearings is 1 8 inch shim or replace as required when these bearings require service check all other slide bearings shims are 1 16 inch thick 4 14 Engine Crankcase Filler Cap drain oil and refill top level EO 1 15 Engine Oil Filter replace filter element 1 18 Vacuator Valve rubber cone on bottom check to be sure cone is clear and undamaged 1 20 Drive belts check condition replace as required 1 22 Rear Hub Level Plug check level and refill as required HF 2 24 Drive Axle Level plug check level and refill as required HF 1 Check torque of all items listed in Torque Chart pg 18 0 Quarterly or 500 Hour Lubrication amp Maintenance include all previous periodic services 17 Fuel Filter Water separator with Drain replace element 1 32 Hydraulic System we recommend that hydraulic fluid be analyzed to determine condition drain and refill reservoir if required 1 33 Hydraulic Reservoir Screen remove clean and install when hydraulic oil is drained 1 Semi Annual or 1000 Hour Lubrication amp Maintenance include all previous periodic services 5 Hydraulic Reservoir Breather Cap clean or replace 1 23 Rear Hub Drain Plug drain and refill item 22 is fill plug HF 2 27 Differential and Planetary Drain Plugs drai
51. on M 1 Retract Quick Switch attachment tilt 2 Align boom head pivot with recess in lever forward to provide clearance attachment Raise boom slightly to Check to be sure lock pin is secured in engage boom head pivot in recess PACA out position with retainer pin 3 Engage Quick Switch attachment 4 Remove retainer pin and slide lock tilt lever backward pin in fully 5 Secure lock pin in locked position using 6 If attachment is equipped swing retainer pin saddles down and pin in place 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 an additional copy must be kept with the attachment if it is equipped with a manual holder Take extra care when engaging securing manipulating transporting and positioning the load Operate a handler equipped with an attachment as a partially loaded handler Pay Ed 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
52. 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 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 pro
53. ould be done at boom assembly however some adjustments may be required after assembly Add shims as required so that front and sides of boom have no more than 1 5mm 06 inch clearance Add shims as required so that rear of boom has more than 3 04mm 12 inch total clearance Number of shims at each pad may vary however shims at bottom front pads must not vary more than one shim between sides Pads must not directly contact shims thus a spacer must be inserted between pad and shims e Use Loctite 242 Gradall P N 1440 3364 on screws when adding or removing shims Boom Chain Check boom chain adjustment With boom horizontal extend boom 1 2m to 1 5m 4 to 5 feet then fully retract boom Measure gap between all bevel washers on extend chain rod and add them together If total of all gaps exceeds 3 04mm 12 inch boom chain will need to be adjusted Adjust as follows A Loosen lock nut on extend chain rod Tighten adjusting nut on extend chain rod until all wash ers are just flat no gap between any washers C Torque lock nut to 100 Ib ft After adjusting check that boom sections and or access holes in side of boom are aligned If they are not retract chain will require adjustment as follows A Fully retract boom B Measure distance between 2 and 3 boom sections Determine amount of misalignment Loosen extend chain lock nut and adjusting nut as far as possible Loosen retract c
54. ove oil film from cylinder walls and dilute lubricant in crankcase Form No 20027 G6 42P Owner Operator Manual Always keep engine cover closed while engine is running 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 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 TRAVEL PEDAL D HIGHEST INCHING TRAVEL SPEED N LOWEST INCHING TRAVEL SPEED 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 The power assisted service brakes are applied only to wheels of the front axle Hydraulic pressure for power assist feature is provided by a bra
55. perator s view e 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 e When adding fluids refer to lubrication section of Manual to determine proper type Complete all required maintenance before operating unit GRADALL Service the unit in accordance with the Lubrication and Routine Maintenance schedule pages 16 0 and 16 1 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 Use extreme caution when checking items beyond your normal reach Use an approved safety ladder Before operating handler com plete all required maintenance Replace or repair all damaged worn or missing components be fore starting or operating handler Failure to properly maintain han dler could cause serious injury or death Use a piece of cardboard or paper to search for leaks DO NOT use bare hands If anyone is injured by hydraulic fluid including penetration of the skin obtain medical help immediately 5 0 WARM UP amp OPERATIONAL CHECKS To be performed at be
56. perly 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 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 Form No 20027 G6 42P Owner Operator Manual 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 WARNING This symbol indicates a hazard which could result in death or serious injury if proper precautions are not taken A CAUTION 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 mirro
57. pers 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 14 6 LOWER WINCH m LOAD The auxiliary control lever is used to control the boom head mounted winch Pull the AUXILIARY lever back to raise winch load push the CONTROL LEVER 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 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 Form No 20027 G
58. 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 could cause damage or in some cases cause the machine to tip over Form No 20027 G6 42P 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 14 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 or Gradall 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 establish range and
59. 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 14 1 Operation 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 Gradall Material Handlers Form No 20027 G6 42P Owner Operator Manual Do not handle a load with Swing Mast attachment until you study amp 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 load with swing mast Do not use the Personnel Work Platform until you study amp understand the
60. r s clean Adjust mirror s as required for maximum WARNING visibility before and during operation Contact The Gradall Company prior m to welding on machine Never permit diesel engine to run out of fuel Doing so can cause severe damage DO NOT burn or drill holes in forks Modifying any part of machine or attachment affects it s capacity and or stability of machine 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 s hotline 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 make sure all controls are in Neutral allow engine to run at low idle for 3 to 5 minutes Stop engine and remove ignition key Block wheels BATTERIES CALIFORNIA PROPOSITION 65 AND RELATED PARTS BATTERY WARNING CONTAIN LEAD Battery posts terminals 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 WASH HANDS AFTER HANDLING State of California
61. raulic failure parking brakes can be released for towing See To Release Parking Brake Page 20 1 8 0 PARKING THE HANDLER Precautions Avoid parking on slopes or near an excavation Park on level ground and block 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 parking on a slope cannot be avoided position the handler at a right angle across the slope straighten rear wheels and block all wheels Parking procedure 1 2 Using service brake stop the handler in an appropriate parking area Move parking brake switch to On Shift forward reverse lever to Neutral Position boom head or attachment on ground Allow engine to cool at idle speed for 3 to 5 minutes stop engine and remove ignition key Block 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 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 Form No 20027 G6 42P Owner Operator Manual Be alert for any increas
62. required 10 Contact your GRADALL Distributor for information concerning oil analysis sample containers are available from several sources Oil companies Oil suppliers e Sampling labs GRADALL 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 20 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 available 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 Manual steering may be possible without power assist steering will be slow and will require much greater force e Response to manual steering will be increased if parking brake is released and front axle drive is bypassed permitting front wheels to roll MOVING SHORT DISTANCES If it is only necessary to move handler a short distance less than 100 feet 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 but less than 200 yards it is permissible to use a vehicle of sufficient capacity to to
63. rmanent 15 5 ats 5 15 5 ats PM 7L Rem erem one rae uns we meeemm Capacities are approximate check level to be sure to level using Mobilfluid 424 GRADALL P N 1440 4535 Fill to level using Mobilfluid 424 OR Citgo Tractor Hydraulic Fluid product code 33310 When replacing foam filled tires replace the complete tire and rim assembly 18 0 To check GRADALL torque values set the torque wrench at 95 of rated torque value and check fastener If the torque wrench releases before the fastener moves assume fastener torque is correct When setting GRADALL torque values use the values given on the following chart Do not exceed allowances TORQUE lubricated ITEM FREQUENCY THREAD SIZE LB RUN MANOR GRADE Boom Slide Bearings front 5 Weeks 250 hrs 3 8 24 5 5 Weeks 250 hrs 1 2 20 5 We Boom Slide Bearings rear If front bearings have 3 8 24 5 TS loose 20 117 Boom Chain Jam Nuts Annually 1500 hrs 1500 hrs 7 84 14 Cab Mounting Bolts upper lower Engine Assembly Flywheel Housing Bolts Annually 1500 hrs 38 48 52 Flexplate Mounting Bolts Annually 1500 hrs 3 8 16 40 45 54 Hydrostatic Trans Bolts Annually 1500 hrs 3 4 10 5 240 265 325 Engine Mounts Annually 1500 hrs M12 76 16 181 Front Axle Motor to Axle Bolts Annually 1500 hrs Hub Assembly
64. speed and release pedal to decrease speed 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 left side of switch to tilt down depress right side of switch to tilt up Auxiliary Control Lever optional This lever is used to control optional hydraulic attachments Follow decal 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 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 and 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 indica
65. t boom fully before loading bucket Loading bucket with boom extended could damage structural members or extension chains 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 Observe all precautions and load capacity limits listed previously when handling loads with light material bucket 14 3 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 approximately one foot above ground and travel carefully to unloading point Turn bucket down to dump load Mast 6 with 48 or 72 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 14 3 gt LOWER FORKS Fhe carriage tilt cylinder is used to tilt the mast and the carriage tilt lever controls mast tilt The auxiliary control lever is used to raise and lower the
66. t 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 Ce eo es LT Do not handle a load with Truss Boom amp Truss Boom with Winch attachment until you study amp understand the Truss Boom amp Truss Boom with Winch Capacity Chart If your handler does not have a Truss Boom amp Truss Boom with Winch Capacity Chart ask your supervisor to get one before using the attachment PRECAUTIONS e Always level forks horizontally before swinging load to side Swinging unleveled forks may result in load slipping from forks e The swing mast attachment has a smaller load capacity than the standard carriage fork attachment Study amp understand the swing mast capacity chart before handling a load with swing mast Read additional capacity information under Capacity heading 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 above ground level See Page 12 0 14 7 Swing Mast Controls F
67. t 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 The heater fan speed is controlled by a knob on the panel to the right of the operator s seat Hot water to the heater can be controlled by a knob on the same panel or a valve in the engine compartment The operator s cab is 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 FORWARD NEUTRAL REVERSE LEVER HOURMETER STEERING WHEEL PARK BRAKE OIL PRESSURE COOLANT TEMP VOLTMETER FUEL GAUGE BOOM CONTROL JOYSTICK HORN BUTTON ATTACHMENT TILT MACHINE LEVEL STANDARD AUX CONTROL LEVER CAPACITY CHARTS OPTIONAL IGNITION SWITCH 4x2 4x4 SWITCH SERVICE BRAKE ACCELERATOR PEDAL INCHING TRAVEL PEDAL TRACTION LOCK SWITCH Form No 20027 G6 42P Owner Operator Manual Never operate the handler unless the overhead guard is in good condition Any modification which adds weight to this machine must be approved by GRADALL to assure compliance with FOPS ROPS certification for this 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
68. tes 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 roatation to START engages starter motor Counter clockwise rotation to OFF stops engine and removes voltage from all 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 Move the lever left to tilt frame to left move the lever right to tilt frame to right Parking Brake Switch This switch controls the application and release of the parking brake Indicator light on switch glows red to indicate brake is applied C esM es LT 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 the EMI Rough Terrain Forklift Safety Manual and the GRADALL Material Handler Safety Manual and view the GRADALL EMI Operator Orientation Video 3 2 Seat Lock Release Lever This lever unlocks and locks seat position adjustment Service Brake Inching Travel Pedal This pedal operates the service
69. ting 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 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 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 Hydraulic Equipment Printed in USA
70. tor 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 arm 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 outward inward at about 459 downward 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 poin
71. uipment This Manual covers recommended operating procedures and basic maintenance checks and services for the G6 42P 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 GRADALL 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 Page 11 0 16 0 Cover Intro TOC 10 0 13 1 14 7 17 0 18 0 20 1 20 2 Cover Date Revision rated page 20 2 to Table Of contents replaced 9140 3525 Decal with 9150 3102 bea Added 9134 2016 amp 9141 3061 Decals 8 FIN to AngusPalm Decal Remov
72. ull throttle have an assistant severe damage to hydraulic system check the Hydraulic Filter Condition Indicator When bar gauge is in red area filter is clogged and hydraulic oil is bypassing filter Filter element must be changed before reaching bypass condition change before indicator reaches red area Complete all required maintenance before operating unit Form No 20027 G6 42P Owner Operator Manual 6 0 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 Minimum 15 PSI 105kPa Normal 50 PSI 345kPa 5 Warm up engine at approximately 1 2 throttle until engine coolant temperature reaches operating range Optional Cold Weather Starting Aids In cold weather situations a supplemental starting aid may be required Gradall approved starting aids
73. w unit after you e Activate Tow Bypass See Below e Release parking brake See Page 20 1 MOVING LONGER DISTANCES WARNING If the handler must be moved more than 200 yards it must be loaded on to a trailer of sufficient capacity Towing handler with all wheels on ground for more than 200 yards TO ACTIVATE TOW BYPASS could cause serious damage to hydraulic drive components Figure 20 1 2 REVERSE RELIEF VALVE LARGE HEX 1 Hold large hex to prevent movement and loosen reverse relief valve cartridge NOTE small hex two full turns Forward relief valve is located on bottom of pump case directly 2 Repeat step 1 for forward relief valve Front axle drive is now bypassed below reverse relief valve 3 Before returning machine to service be certain to return relief valve cartridges to original position Form No 20027 G6 42P Owner Operator Manual 20 1 RELEASE PARKING BRAKE MERITOR AXLE 1 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 20 2 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 by hand until it just makes contact with guide pin
74. wing forks left Form No 20027 G6 42P Owner Operator Manual A WARNING PRECAUTIONS 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 four feet above ground See Page 12 0 Do not handle a load with Mast attachment until you study amp 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 PRECAUTIONS e Read amp understand additional capacity information under Capacity heading e Always level forks horizontally before swinging load to side Swinging unleveled forks could result in load slipping from forks e Because 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 above ground See Page 12 0 14 4 Swing Forks Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See Page 14 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 approximately one foot above ground Inspect supporting surface at delivery po

g6-42p material handler owner/operator manual

Contents

Download Pdf Manuals

Related Search

Related Contents