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Operation 91474003

1. T EET NN MODEL MODEL UTC NN LEVEL GRADALL HANDLER BEFORE LIFTING ABOVE 4 FT p G6 42A G6 42A Er a eerie mwm LLL semi M rr n M BACK FRONT we s wo amp PES Ns NG E b so 58 ASH ELI pm 20 25 S 2 8 E S aks AE Debe EMEN SX ERIN AENA 2 jum 320 BEES CET M 218 3 he EXPE 8178 Q a y roll 8 18 adet Le A vi M oOo LR et Be WOW wo wr 1 2 5 USE WITH 9140 5101 48 5140 8024 WINCH 4 000 LB MAX CAPACITY 9140 5079 72 SLOPE PILER CARRIAGE nasao paramo BACK FRONT Elevation Numbers at left side of sample chart represent elevation to top of horizontal fork as measured from level ground 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 extensio
2. WARNING NEVER OPERATE MACHINE WITHOUT CONSULTING PROPER CAPACITY CHART FOR THE CARRIAGE FORK COMBINATION BEING USED 9132 3030 ITA LI I G6 42A G6 42A Ep p ag Uy REN PERIERE w Un E E E a e 40 60 w 2 50 NE RG RES SO ow 1 v2 il 35 N 30 24 2 EXE 20 8 1 CERA mi 120 Ep z Si je a0 10 iL ME gt zi F USE WITH o 4 28 32 32 28 24 20 16 12 8 4 o 9140 5073 48 CARRIAGE USE WITH 9140 5101 48 9140 5024 WINCH 4 000 LB MAX CAPACITY 9140 5079 72 SLOPE PILER CARRIAGE sure V FRONT Located on dashboard P N 9147 3139 Located on right cab wall and cab fender P N 9132 3030 WARNING 4 ONLY TRAINED AND AUTHORIZED PERSONNEL MAY OPERATE THIS MACHINE 2 BEFORE OPERATING READ AND UNDERSTAND ALL CAPACITY CHARTS OPERATOR MANUALS AND SAFETY MANUALS IF MANUALS ARE NOT AVAILABLE CONSULT AN AUTHORIZED GRADALL DEALER UNDERSTAND ALL CONTROLS IN CAB AND CHECK FOR PROPER OPERATION CLEAR LOOSE OBJECTS OFF MACHINE AND SOUND HORN BEFORE STARTING ENGINE 3 OPERATOR MUST BE SEATED WITH SEAT BELT FASTENED ASSURE FORWARD REVERSE LEVER IS IN NEUTRAL PARK BRAKE APPLIED AND ALL HYDRAULIC CONTROLS ARE IN NEUTRAL BEFORE IGNITION SWITCH IS TURNED ON 4 DO NOT OPERATE M
3. CAP 6 6 1 0 42 46 24 24 6 9 SHIPPED with 48 CARRIAGE PIN 9140 5073 TZ CARRIAGE PIN 9140 5074 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 TO BUCKET LIP HEIGHT TRUSS BOOM amp WINCH DIMENSIONS A amp D REFER TO HOOK CENTER WEIGHT IS BASED ON SP L SWING MAST FORKS APPROX 2308 PER PAIR PLATFORM DIMENSIONS amp D REFER TO CENTER OF FLOOR FORKS RATED LESS THAN THE ATTACHMENT CAPACITY SHOWN ABOVE DECREASE CAPACITY OF ATTACHMENT TO THAT OF FORKS FORKS RATED MORE THAN ATTACHMENT CAPACITY DO NOT INCREASE ATTACHMENT CAPACITY 9147 3131 8 Located right cab wall P N 9147 3131 LUBRICATION AND MAINTENANCE CRADALL 6 42A SERVICE INTERVALS DALY WEERLY EVERYS SMO 6MO YEARLY LUBRICANT TYPE MATERIAL HANDLER OR WKSOR OR OR 1oHRS s0HRs 25085
4. Neutral Observe Hydraulic Filter Bypass Indicator with engine running at OIL CLEANLINESS IS CRITICAL full throttle Replace filter elements if necessary The filtration system is designed to maintain a minimum ISO 3 Obtain a container to receive waste oil and a CLEAN container to receive oil cleanliness level of 18 15 sample 4 With gauge removed from hose attach mini check and hose to test port located above priority valve See figure 14 1 Hose end must be positioned in waste oil container 5 Allow at least one pint of oil to flow into waste oil container to eliminate any contamination from hose 6 Move hose to CLEAN container to collect sample for analysis 7 Return hose to waste oil container and disconnect adapter from mini check test port 8 Cover sample container immediately with CLEAN cap 9 Stop engine and check oil level in reservoir and replenish as required For ease of filling reservoir use a funnel with a hose or flexible tube for best results 10 Contact your GRADALL Distributor for information concerning oil analysis Oil sample containers are available from several sources Oil companies Oil suppliers TAKE HYDRAULIC SAMPLE FROM THIS PORT e Sampling labs Figure 14 1 Form No 20036 G6 42A Owner Operator Manual 1 4 0 LOADING amp SECURING FOR TRANSPORT Loading amp Securing Handler For Transport 1 2 3 Level the material handler prior to loading Us
5. BATTERIES AND RELATED PARTS CONTAIN LEAD CALIFORNIA PROPOSITION 65 BATTERY WARNING 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 WARNING Battery posts terminal and related accessories contain lead and lead compounds chemicals known to the State California to cause cancer and reproductive harm Form No 20036 G6 42A Owner Operator Manual Contact The Gradall Company prior to welding on machine 1 1 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 mL i N Ni id Boom Holes Carriage Forks 1 2 CO SY MUT Form No 20036 G6 42A Owner Operator Manual DECAL LOCATIONS Figure 2 1 1 2 3 4 5 6 7 8 9 10 2 0 9114 3282 9114 3280 9140 3569 9114 3288 9132 3030 9055 3027 8060 3022 7733 3027 9114 3283 9114 3286 CRA
6. 35 35 LUBRICATION NOTICE e After greasing machine cycle all functions several times to distribute lubricants Perform this maintenance procedure without attachment or forks installed e Apply a light coating of engine oil to all linkage pivot points e Clean lubrication fittings before lubricating Intervals shown are for normal 8 hour day usage and conditions Adjust intervals for abnormal usage and conditions e Drain engine and gear cases after operating when oil is hot e Check lubricant levels when lubricant is cool For ease of filling hydraulic reservoir use a funnel with a hose or flexible tube for best results Clean filter and air cleaner housing and reusable elements using solvent or diesel fuel Dry components thoroughly using lint free cloth 17 4 CAUTION 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 obtain maximum service life Frequency headings in the following schedule indicate a calender limit and an operating hour limit Perform service at whichever interval occurs first Lube No of SymbolPoints Daily or Shift 10 hour Maximum Lubrication amp Maintenance 12 Air Cleaner Element Condition Indicator check for clogged condition red band showing and clean or replace element as required 1 13 Hydraulic Return Filter Condition Indicator check indicator with oil at no
7. The parking brakes are spring applied and hydraulically released Pressure 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 the transmission will not engage forward or reverse 7 0 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 A WARNING Always move parking brake switch to On position before leaving cab Never stop engine while traveling Parking brake will be fully applied and unit could stop abruptly A sudden stop could cause load loss Always ensure that transmission control lever is in neutral before releasing park brake Releasing park brake in either forward or reverse could cause the machine to move abruptly GRADALL PARKING THE HANDLER Precautions Avoid parking on slopes or near an excavation Park on level ground and chock wheels Avoid parking on roads or highways If it cannot be avoided be sure to display warning flags during day and flares or flashing lights at night Position attachment on ground never leave machine with boo
8. Figure 13 4 SWING The carriage tilt cylinder is used to tilt the LEFT swing forks up and down and the carriage tilt lever controls fork tilt AUXILIARY CONTROL LEVER Th ili trol dt SWING e auxiliary control lever 1 used to swing RIGHT the forks to the left and right Pull lever back to swing forks right push lever forward to swing forks left Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See page 13 1 2 Install swing forks attachment on boom head 3 Connect auxiliary hydraulic hoses to swing forks attachment Operation e Always position forks straight ahead before engaging load e To travel with load keep forks in straight ahead position and lower load to 1 2m 4 feet or less above ground allowing for best visibility e Inspect supporting surface at delivery point and have it leveled if necessary e Use a signal man to 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 13 5 TILT
9. dL GRADALL OWNER OPERATOR MANUAL GRADALL G6 42A 9147 4003 June 2003 Starting Serial No 0190001 thru 0190457 amp 0160000022 thru Current Original Issue 3 01 Form 20036 Revised Issue 6 03 CORPORATE OFFICE GRADALL DIVISION JLG INDUSTRIES INC JLG INDUSTRIES INC 1 JLG DRIVE 406 Mill Avenue S W McConnellsburg PA New Philadelphia OH 17233 9533 44663 USA USA Telephone 717 485 5161 Telephone 330 339 2211 Fax 717 485 6417 Fax 330 339 8458 G6 42A MATERIAL HANDLER OWNER OPERATOR MANUAL COVERING OPERATION amp PERIODIC MAINTENANCE r ce I n g CA mate ri 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 Company JLG COVERS MATERIAL HANDLER G6 42A Form No 20036 STARTING SERIAL NUMBER Part No 9147 4003 0190001 thru 0190457 amp 0160000022 thru Current Revised 6 13 03 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 complie
10. e If necessary perform a dry run unloaded of delivery to determine best position for handler e Use a signal person to assist in positioning the load if necessary Form No 20036 G6 42A Owner Operator Manual PRECAUTIONS e Always level forks horizontally before swinging load to side Swinging unlevel forks could result in load slipping from forks The swing mast attachment has a smaller load capacity than the standard fork attach Study and understand the swing mast capacity chart before handling a load with swing mast e Read X additional information under Capacity heading on chart e Because the swing mast increases lift height and can swing load to side it is especially important to level handler before lifting a load more than 1 2m four feet above ground level See page 11 0 Do not handle a load with Swing Mast attachment until you study and understand the Swing Mast Capacity Chart If your handler does not have a Swing Mast Capacity Chart ask your supervisor to get one before using the attachment Observe all precautions and load capacity limits when handling loads capacity 13 7 Personnel Work Platform The material handler operator and personnel in the platform must read and understand the separate personnel work platform manual included with the attachment prior to using the platform Capacity The Gradall personnel work platform is des
11. ask your supervisor to get one before using the attachment GRADALL e Tilt carriage to left or right to align forks with load and engage load e Raise load slightly and then level carriage e Travel with load lowered to travel position 1 2m 4 feet or less above ground Boom Head Mounted Winch Capacity The boom head mounted winch maximum load capacity is shown on the standard carriage capacity chart However maximum capacity may be used only in areas where it does not exceed capacities shown on standard carriage fork capacity chart located on dashboard Also note that maximum winch capacity is less than carriage fork maximum capacity Capacity rating is based on load being lifted and suspended vertically from the boom and with no load on forks Observe the following Special Precautions e Never drag the load lift vertically e Use tag line to guide and steady a suspended load Tag lines must be long enough to keep helpers clear of load and handler e Beware of wind Wind can cause a suspended load to swing and cause dangerous side loads even with tag lines e Start travel turn and stop slowly to prevent load from swinging e Weight of all rigging slings etc must be included as part of load e Do not attempt to use handler frame leveling to compensate for load swing Attachment Tilt Controls Figure 13 6 LOWER WINCH LOAD D AUXILIARY The auxiliary control lever is used to CONTROL LEVER control the boom
12. c EE 2 0 Decals OPERATORS GAB SR Ea DA QU RE AA Ge a a RC 3 0 Cab Control amp Instrument Identification CHECKS amp SERVICES BEFORE STARTING ENGINE 4 0 WARM UP amp OPERATIONAL 5 0 ENGINE OPERATION saver Rap NE Eh RE Cr Er Fe AR Sv S 6 0 Starting the Engine Cold Weather Starting Aids Battery Boosted Starting Normal Engine Operation Stopping the Engine BRAKE SYSTEM 7 0 General Service Brake Park Brake PARKING THE HANDLER ccccccceeeuseuccseeuenecuseeuaueeueneeuneucanesaenes 8 0 STEERING SYSTEM ra d abad xa wee 9 0 DRIVE TRAIN C s ucc fec ce at 10 0 LEVELING THE HANDLER e nera anxia a rima mi a ane 11 0 OPERATING PROCEDURE amp TECHNIQUES 12 0 Hydraulic Controls Rated Capacity Chart ATTACHMENTS 55 2 en satus RE URS ade 13 0 Approved Attachments Non Approved Attachments Carriage Fork Capacities Other Attachment Capacities Attachment Installation Attachment Operation OBTAINING HYDRAULIC OIL SAMPLE FOR ANALYSIS 14 0 LOADING amp SECURING FOR 15 0 MOVING HANDLER IN EMERGENCY 0 cece cece eee eH 16 0 Moving Short Distances Moving Longer Distances MAINTENANCE SECTION 17 0 Nomenclature Lubrication
13. 4 o clock and 8 o clock Put plugs aside 5 Tighten each release screw revealed by the plugs lightly until it just makes contact with guide pin 6 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 360 approximately 67 n m 50 ft Ib Larger turns could cause components to bind and cause brake failure 7 Repeat this procedure on other side of differential Parking brake should be released TO RESTORE PARKING BRAKE Make certain engine is stopped and all wheels are blocked Loosen each release screw only 1 4 turn at a time in sequence until each screw has lost contact with guide pin Then back out each screw until it bottoms out against the stop Install plugs over each release screw Repeat procedure on other side of differential Parking brake should be restored to operation DANA AXLE Figure 16 2 AXLE MANUAL RELEASE steps 1 3 Block wheels before performing this procedure 1 Loosen the nuts 37 of the screws 36 for the manual release of the braking units Draw the nuts back about 6mm tecum 2 Tighten screws 36 until they are seated on the driving plate 10 3 Using a wrench tighten two screws 36 in an alternate manner by 1 4 turn at a time in order to compress the Belleville washer 24 and release the braking discs The stroke required for brake release correspon
14. 500 HRS 1000 HRS 1500 HRS SPECIFICATION Diesel Engine Air Cleaner Element Check Fuel Fille Change Engine Oil Filler Change Engine Oi Check Change SAE 15140 CHICOT Coolant Check Change Ethylene sel Fuel Fil No 2 Diese Fuel Check Change Mobil 424 Change Check Change Mobil 424 Axle Lubh Center Sedi Check Change Mobil 24 Planetary Hubs Check Change Mobi 424 Hydraulic System Lubricant Change Filter Change BreatherFiler Change Grease Fittings Aes 6 P s Ea Mystik Tetimoly Head Pivot 2 Pis es Mystik Tetimoly Boom Pivot 2 Ps Grease Mystik Tetimoly Cylinder Pins 13 Pts Grease Mystik Tetimoly Drive Shafts 1 PL Ea Grease Mystik Tetimoly Extend Chain Sheave 1 Pt Grease Mystik Tetimoly Quick Switch Pin 1 PL Grease erimay Chain Sheave 1 Pt Grease Boom Front Bottom Bearing Pads Grease Check Al Other Bearing Pads Grease Extend Retract Chains Check Options And Attachments Stabilizer Cylinder 3 Pts Grease Mystik Tetimoly Attachment Pivots And Pins Grease Mystik Tetimoly Tires 180024 12 Ply Check 85 PSI 448 KPa 1300824 Radial Check T0 PSI 463 KPa 18525 12 Ply Check 58 PSI 400 KPa Lug Nut Torque Torque E Use this chart in conjunction with the Lubrication amp Maintenance and Recommended Lubricants amp Capacities sections of the Owner Operator Manual Service intervals may need to be more frequent than those shown depending upon application severity Consult your Gra
15. COUNTER CLOCK AUXILIARY WISE The carriage tilt lever controls carriage tilt CONTROL LEVER TILT The auxiliary control lever is used to tilt CLOCK slope piler carriage Push lever forward WISE to tilt carriage counter clockwise pull lever back to tilt clockwise Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See page 13 1 2 Install slope piler carriage on boom head Operation e Connect auxiliary hydraulic hoses to slope piler carriage attachment e Approach load with forks centered on load and stop handler e Level handler before tilting carriage to engage load 13 4 PRECAUTIONS Read and understand additional capacity information under Capacity heading e Always level forks horizontally before swinging load to side Swinging unlevel 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 1 2m four feet above ground See page 11 0 PRECAUTIONS e Level handler before tilting carriage to engage load e Always level handler before lifting a load more than 1 2m four feet above ground See page 11 0 Do not handle a load with Slope Piler Carriage attachment until you study and understand the Slope Piler Carriage Capacity Chart If your handler does not have a Slope Piler Carriage Capacity Chart
16. Cooling System drain flush and refill on basis of period suggested by anti freeze manufacturer and add Liquid Coolant Additive refer to John Deere manual for coolant conditioner ratio DETAILED SERVICE INSTRUCTIONS ARE CONTAINED IN THE GRADALL SERVICE MANUAL FOR YOUR PARTICULAR MATERIAL HANDLER Form No 20036 G6 42A Owner Operator Manual 17 2 RECOMMENDED LUBRICANTS amp CAPACITIES Boom Bearing Paths NLGI 2 Coolant Additive refer to engine man coolant additive Engine Cooling System 50 50 Permanent 15 5 qts 14 7 L Engine Crankcase EO engine oil All Year 15W 40 CD Front Rear Axle MIL L 2104D 14 5 gts 13 8L Carraro Center Section HF hydraulic fluid All Year 24 4 pints 11 5 L Each Wheel End HF hydraulic fluid All Year 3 2 pints Dana Center Section HF hydraulic fluid All Year 13 0 pints Each Wheel End HF hydraulic fluid All Year 3 4 pints Fuel Tank DF diesel fuel All Year 2 38 gal 143 8 L Grease Fittings HM extreme pres lube All Year NLGI 2 P N 1440 4595 Hydraulic System HF hydraulic fluid All Year NE ERE 43 gal 163 L Capacities are approximate check level to be sure Fill to level using Mobilfluid 424 GRADALL P N 1440 4535 Fill to level using Mobilfluid 424 OR Citgo Tractor Hydraulic Fluid product code 33310 TORQUE CHART To check GRADALL torque values set the torque wrench at 95 of rated torque value and check fastener If the torque wrench rele
17. No 20036 G6 42A Owner Operator Manual NOTE Some attachments may not be approved for use with certain machine models 12 2 How to read a Capacity Chart When reading the capacity chart you must check to be sure the correct model number is listed See figure 12 5 The next thing to look for is that the part number of your attachment is listed under the Use With section Identify and find the amount of boom extension required along with the angle of the boom Trace the boom extension arc down until it intersects with the appropriate boom angle If the intersection of the boom extension arc and the boom angle line occur within a weight region the value within that region is the maximum capacity for that particular lift If the intersection occurs on a bold line separating capacity regions the smaller of the two values must be used The regions are clearly marked with heavier outlines as shown on page 12 4 If you do not have the correct capacity chart for your machine and or attachment contact your Distributor or Gradall to order one Example A contractor has purchased a G6 42A with the 48 Slope Piler Carriage Attachment See figure 12 5 He knows his attachment may be used with this model since the attachment part number 9140 5101 matches the attachment part number stamped on the machine Serial Number Plate He also knows that the Capacity Chart is correct since it is clearly marked for use with a G6 42A and that th
18. TO NEGATIVE POST ON BOOSTER BATTERY CONNECT OPPOSITE END OF NEGATIVE JUMPER CABLE TO GROUND POINT ON MACHINE AWAY FROM DISCHARGED BATTERY FOLLOW STANDARD STARTING PROCEDURES REMOVE CABLES IN REVERSE ORDER AFTER MACHINE HAS STARTED 9114 3285 2 4 Located on frame below engine cover P N 9114 3284 Located on frame below 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 f CAUSE BURNS 8060 3026 Located in engine compartment P N 9114 3281 Located on radiator P N 8060 3026 GRADALL 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 8060 3022 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 cab fender P N 8060 3022 FULL ADD HYDRAULIC OIL LEVEL CHECK OIL LEVEL WITH HANDLER LEVEL AND ALL CYLINDERS RETRACTED 2 5 GALLON BETWEEN ADD AN
19. 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 When traveling at high rates of speed use two wheel front steer mode and slow the machine prior to turning Do not change steer mode while the machine is traveling Change the steer mode only when machine is stopped Always look in the direction of travel Reduce speed and be especially careful when traveling in reverse and or turning Bring the machine to a complete stop before changing the direction of travel Travel in reverse only at slow rates of speed When turning the forks on the four wheel steer machine sweep through an arc beyond the turn radius of the tires Maintain adequate clearance between the forks load and other objects If load or conditions obstruct view use a signal person when lifting carrying or placing a load Loose clothing can get caught in moving machinery and can also cause accidental actuation of controls Dress properly for the job Be alert to any unusual response to controls If unusual response is noticed position handler in a safe area lower forks to ground apply parking brake stop
20. detailed information including boom chain checks and adjustments see the appropriate Service Manual 17 4 Form No 20036 G6 42A Owner Operator Manual INSPECTION AND MAINTENANCE LOG Hourmeter Comments Reading 18 0 ARADA HAND SIGNALS Standard Signals When handler work conditions require hand signals they shall be provided or posted conspicuously for the use of both signalman and operator No handler motions shall be made unless signals are clearly understood by both signalman and operator Special Signals When signals for auxiliary equipment functions or conditions not covered are required they shall be agreed upon in advance by the operator and signalman Instructions When it is desired to give instructions to the operator other than provided by the established signal system all handler motions shall first be stopped EMERGENCY STOP With both arms extended laterally hands open downward move arms back and STOP With either arm extended laterally hand open downward move arm back and forth EXTEND TELESCOPIC BOOM With RETRACT TELESCOPIC BOOM With both hands clenched point thumbs both hands clenched point thumbs outward inward CLOSE BUCKET Hold one hand OPEN BUCKET Hold one hand closed and stationary Rotate other hand in small vertical circle with forefinger pointing horizontally at closed hand open and stationary Rotate other hand in small vertica
21. head mounted winch RAISE Pull the lever back to raise winch load WINCH push the lever forward to lower winch LOAD load Installation Procedure 1 Install winch on boom head and connect hydraulic hoses at winch motor 2 Position winch hook directly above balance point of load and secure using appropriate rigging Operation e Attach tag lines to load and transport load to delivery site e While helpers guide load with tag lines position load at delivery point Form No 20036 G6 42A Owner Operator Manual A side load or a swinging load could cause the handler to tip over and or damage the boom PRECAUTIONS e Maximum winch load capacity is reduced from normal carriage fork load rating e Always level handler before lifting a load See page 11 0 e Travel with load and boom lowered to travel position 1 2m 4 feet or less above the ground e Always lower load to rest before leaving handler Do not handle a load with Boom Head Mounted Winch attachment until you study and understand the Boom Head Mounted Winch Capacity Chart carefully If your handler does not have a Boom Head Mounted Winch Capacity Chart ask your supervisor to get one before using the attachment 13 5 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 extens
22. leveled This method must be chosen if it will be necessary to move the handler from its position after the load has been raised over 1 2m 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 1 2m 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 10 to left or right to compensate for uneven ground conditions Optional rear axle stabilization is available for Material Handlers covered by A WARNING this manual This system includes a hydraulic cylinder attached to the frame and the rear axle as well as flow restricting valving This system dampens If handler cannot be leveled rear axle
23. location and shut down A CAUTION When traveling at higher speeds use 2 wheel front steering 3 2 CHECKS amp SERVICES BEFORE STARTING ENGINE To be performed at the beginning of each work shift e Check to be sure the material handler is equipped with the proper load capacity chart and that it is legible before operating 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 operator 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 Optional Turbo Charged Engine Shown 4 0 Service the unit in accordance with the Lubrication and Routine Maintenance schedule pages 17 1 and 17 2 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
24. oscillation whenever the boom is raised over 45 from level using leveling system do not However the system never locks the rear axle and is not designed to attempt to raise or place load increase lateral stability Have surface leveled Leveling Procedure Position machine in best location to lift or place load position forward reverse lever in neutral and apply parking brake Observe level indicator to determine whether machine must be leveled and level machine with the machine level lever 11 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 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 i
25. volts 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 not gun engine before shut down This practice causes incompletely burned fuel to remove oil film from cylinder walls and dilute lubricant in crankcase Form No 20036 G6 42A Owner Operator Manual 6 1 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 Service Brakes Depressing the service brake pedal 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
26. 406 MILL AVES WNEW PHIEADELE HA MADE INU SA 406 MILL AVE S W NEW PHILADELPHIA OHIO MADE IN U S A 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 Ane OE O 90553039 9015 3001 O Located on Personnel Work Platform Located on attachment P N 9055 3033 P N 9015 3001 2 6 OPERATOR S CAB The 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 is fully secured when operating the handler The operator s seat is equipped with a seat belt and includes fore and aft adjustment to compensate for variations in operator size The adjustment release lock is located 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 th
27. ACHINE WITHOUT PROPER CAPACITY CHART IN PLACE 5 BEFORE MOVING BE SURE OF A CLEAR PATH AND SOUND HORN WATCH FOR PEDESTRIANS AND OBSTRUCTIONS CHECK OVERHEAD AND SIDE CLEARANCES ALWAYS LOOK IN DIRECTION OF TRAVEL 6 START TURN AND BRAKE SMOOTHLY REDUCE TRAVEL SPEEDS FOR TURNS SLIPPERY OR UNEVEN SURFACES AVOID RUNNING OVER LOOSE OBJECTS OR HOLES IN THE ROADWAY SURFACE FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF SERIOUS INJURY READ AND OBSERVE THE FOLLOWING 7 WHEN TRAVELING WITH LOAD FULLY RETRACT BOOM AND PLACE FORKS IN CARRY POSITION APPROX 12 ABOVE GROUND TILT CARRIAGE BACK SLIGHTLY TO CRADLE LOAD USE EXTREME CAUTION WHEN TURNING 8 ON INCLINES TRAVEL WITH LOAD UP GRADE 9 DO NOT USE BOOM AS WALKWAY 40 USE TWO HANDS WHEN CLIMBING ON MACHINE 11 USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM FOR LIFTING PERSONNEL NO RIDERS ON MACHINE FORKS LOAD OR OTHER LIFTING ATTACHMENTS AT ANY TIME DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL HANDLER PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN THE CAB DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM 12 KEEP OTHERS AWAY FROM MACHINE WHILE OPERATING DO NOT STAND UNDER BOOM OR LOAD 43 USE EXTREME CARE WHEN HANDLING LONG HIGH OR WIDE LOADS DO NOT HANDLE UNSTABLE OR LOOSELY STACKED LOADS 14 FORKS TO BE CENTERED UNDER LOAD AND SPACED APART AS AS POSSIBLE 15 BEFORE ADJUSTING OR SERVIC
28. CALS A WARNING PINCH POINT KEEP OUT REACHING INTO BOOM HOLES AND OTHER PINCH POINTS CAN CAUSE SERIOUS INJURY OR DEATH WARNING EXHAUST SYSTEMS CAN BE HOT KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT HOT EXHAUST COMPONENTS CAN CAUSE SEVERE BURNS duds 8060 3037 A Located on right rear frame P N 9114 3280 Located on boom P N 8060 3037 WARNING READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED Located on left side of boom PERSONNEL WORK PLATFORM ALL PERSONNEL IN PLATFORM MUST WEAR A FULL BODY HARNESS WITH P N 9100 3031 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 Located on boom head amp personnel work platform WARNIN P N 9055 3026 MAXIMUM OCCUPANCY THREE 3 PEOPLE DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL HANDLER PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN CAB FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH 9055 3031 REV A ATTACH LANYARD HERE Located on Personnel work platform Located on work platform P N 9055 3031 P N 9055 3032 GRADALL GRADALL
29. D FULL MARKS 9140 3569 Located on hydraulic reservoir P N 9140 3569 GRADALL Located on left cab wall P N 9114 3283 MADE IN THE USA WARNING 7733 3027 Located on left cab wall P N 7733 3027 WARNING DIESEL FUEL IS FLAMMABLE EXTINGUISH ALL OPEN FLAME AND SMOKING MATERIALS WHEN REFUELING INJURY OR DEATH COULD RESULT FROM FIRE iuto 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 READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN 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 9055 3027 REV A Located on both sides of frame near axles and boom head P N 9114 3282 Form No 20036 G6 42A Owner Operator Manual Located on mud guard P N 9055 3027 2 5 DE
30. DALL Warning Decal Pinch Point Warning Decal Exhaust System Oil Level Decal Hydraulic Oil Decal Warning Decal Capacity Chart Warning Decal Lifting Personnel Danger Decal High Voltage Made in USA Decal Warning Decal No Riders Warning Decal Diesel Fuel 9108 3492 9055 3028 9147 3131 9150 3102 9147 3217 9140 3618 9147 3139 9147 3162 9141 3061 Oil Warning Decal Warning Decal Safe Operation Serial No amp Attaching Plate Boom Operation Decal Service Instruction Plate Load Chart Cover Carriage Chart G6 42A Capacity Chart Ignition Decal S N 0160001283 thru Current GRADALL Figure 2 2 Yow v 8060 3026 9114 3281 9114 3284 9114 3285 9140 3573 9147 3133 9147 3132 9114 3290 9100 3031 VIEW C C Caution Decal Cooling System Warning Decal Moving Parts Warning Decal Battery Instruction Decal Jump Start Hydraulic Fluid Decal G6 42A Decal Gradall Decal Warning Decal Attachment Boom Angle Decal Form No 20036 G6 42A Owner Operator Manual VIEW 0 0 8060 3037 9055 3026 9100 3016 9100 3018 9112 3042 9100 3020 9112 3044 9116 3077 Warning Decal Pinch
31. ING PLACE FORWARD REVERSE LEVER IN NEUTRAL REST BOOM ON GROUND OR SUPPORT SET PARKING BRAKE SHUT OFF ENGINE AND CHOCK WHEELS 16 BEFORE LEAVING MACHINE UNATTENDED PLACE FORWARD REVERSE LEVER IN NEUTRAL LOWER BOOM SET PARKING BRAKE AND SHUT OFF ENGINE CHOCK WHEELS IF MACHINE MUST PARK ON AN INCLINE 17 LEVEL MACHINE BEFORE LIFTING ANY LOAD ABOVE 4 FEET IF EQUIPPED WITH FRAME LEVELING 18 OPERATOR PROTECTION SUCH AS HARD HATS SAFETY GLASSES AND OR HEARING PROTECTION SHOULD BE WORN WHEN JOB CONDITIONS WARRANT ALWAYS USE SEAT BELT 19 IMPROPER USE OF MACHINE COULD RESULT IN MACHINE TIPPING OVER IF MACHINE STARTS TO TIP OVER DO NOT LEAVE OPERATORS SEAT LEAN AWAY FROM TIP amp BRACE YOURSELF 20 KEEP MIRROR S CLEAN AND PROPERLY ADJUSTED OBJECTS IN MIRROR ARE CLOSER THAN THEY APPEAR 9055 3028 REV A 2 2 Located on right cab wall P N 9055 3028 GRADALL g IS A REGISTERED TRADEMARK FOR HYDRAULIC EQUIPMENT BUILT BY THE GRADALL CO MANUFACTURED IN THE USA MATERIAL HANDLER 406 MILL AVE SW NEW PHILADELPHIA OHIO 44663 MODEL C6 4ZA MACHINE SERIAL NO ENGINE SERIAL NO WEIGHT 19430 LBS RELEASED FROM FACTORY THIS TRUCK MEETS THE DESIGN SPECIFICATIONS ESTABLISHED IN AMERICAN NATIONAL STANDARDS FOR POWERED INDUSTRIAL TRUCKS PART Ill ASME B56 6b 1998 CAPACITY WITH STANDARD i 48 amp 72 CARRIAGE
32. NE RADIATOR CONTROL VALVE HYDRAULIC OIL COOLER TRANSMISSION OIL COOLER REAR AXLE PRIORITY VALVE AIR CLEANER STEERING CYLINDER REAR DRIVE SHAFT STEER SELECT VALVE FRONT DRIVE SHAFT STEERING CYLINDER BOOM HEAD THIRD BOOM SECTION SECOND BOOM SECTION FIRST BOOM SECTION CROWD CYLINDER OPERATOR S CAB AIR CLEANER LIFT CYLINDER COMPENSATION CYLINDER COUNTERWEIGHT TIE DOWN LUGS REAR LUG NUTS FUEL TANK FRONT LUG NUTS ATTACHMENT TILT CYLINDER QUICKSWITCH 17 0 LUBRICATION amp ROUTINE MAINTENANCE Lubrication Symbols DIESEL FUEL ENGINE FUEL HYDRAULIC FLUID MOLY LUBE extreme pressure IMPORTANT NOTICE Be certain to check extend chain FAILURE TO USE GRADALL SYMBOLES Lube Fitting adjustment every 5 weeks or 250 hours and adjust as required Chain HYDRAULIC FILTER ELEMENTS Other Service damage can occur if chain is not COULD VOID WARRANTY Service Both Sides adjusted properly 18 EVE
33. Point Warning Decal Lifting Personnel 1 Decal 2 Decal 3 Decal 4 Decal 5 Decal 6 Decal DECALS GENERAL CIFIC ATTACHMENT ON MACHINE GRADALL DEALER DETERMINE BOOM MATCH WITH BOOM ANGLE TO FIGURES SHOWN ARE STACKING CAPACT RATED LIFTING CAPACITIES SHOWN ARE WITH MAC 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 DO NOT EXCEED RATED LIFT CAPACITY LOADS AS UNSTABLE DANGEROUS MACHINE CONDITIONS WILL RESULT DO NOT TIP THE MACHINE FORWARD TO DETERMINE ALLOWABLE LOAD CERTAIN CARRIAGE FORK COMBINATIONS MAY CAUSE HANDLER TO TIP WITHOUT LOAD WHEN EXTENDED INTO NO OPERATION ZONE AS NOTED ON CAPACITY CHART LEVEL GRADALL HANDLER BEFORE LIFTING ABOVE 4 FT sw aw j C CAPACITY PACITY CHART G R A D A L L suos _ Located on dashboard P N 9140 3618 Va Feuer an ee MODEL MODEL FROM ALL CAPACITIES pcm 1 A Y pee 9150 3102 REV Located on right cab wall P N 9150 3102
34. ab machine configuration NOTE Relevant S A E Recommended Practices S A E J1040 for ROPS S A E J231 for FOPS 3 0 OPERATOR S CAB Accelerator Pedal Depress pedal to increase speed and release pedal to decrease speed A WARNING 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 A brief description of controls and pull lever back to tilt up instruments is provided here as a convenience for the operator These descriptions DO NOT provide complete operation instructions Read amp understand this Manual and the GRADALL Auxiliary Control Lever optional This lever is used to control optional Material Handler Safety Manual hydraulic attachments Follow decal instructions for lever handler movements Attachment Tilt Switch optional Depress left side of switch to tilt down depress right side of switch to tilt up 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 display
35. ad 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 fork swing and load when turning 9 0 A WARNING Be alert for any increase in effort needed to steer If any difference is noted notify maintenance personnel immediately If power assist feature should fail for any reason IT WOULD BECOME VERY DIFFICULT TO STEER For this reason it is extremely important that you NEVER TURN ENGINE OFF WHILE TRAVELING In the event power steering fails stop as soon as possible Do not drive handler until problem has been corrected Use only 2 wheel steer when traveling at high speeds Never use 4 wheel circle steer at high speeds sharp turns could cause machine roll over GRADALL This model material handler is equipped with powershift transmission With this type of transmission the operator simply selects a gear selects the direction of travel releases brakes and depresses the accelerator pedal to move the handler Operation Gear Selection A three speed transmission is used on machines equipped with the naturally aspirated engine Each gear is available in both forward and reverse Turbocharged engines use a four speed transmission These transmissions have four forward gears and three reverse gears Gear selection is accomplished by rotating the twist grip handle on the transmission control
36. ame as standard carriage without fork positioner Refer to Attachment Capacity Chart Capacity varies with boom extension and elevation positions lt gt OPEN FORKS CLOSE FORKS Controls Figure 13 1 AUXILIARY CONTROL LEVER The auxiliary control lever is used to adjust fork position Pull lever back to close forks push lever forward to open forks Installation Procedure 1 Remove standard carriage fork combination or other attachment from boom head See Attachment Installation page 13 1 2 Install carriage fork combination with positioner 3 Connect auxiliary hydraulic hoses to positioner cylinders Operation e Always adjust fork position before engaging load Moving forks after engaging load could cause load to fall from forks Light Material Bucket Capacity Maximum capacity of light material 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 13 2 LOWER LOWER LOWER RAISE BUCKET BUCKET gt BUCKET BUCKET LIP T LIP LIP LIP RAISE RAISE BUCKET BUCKET LIP LIP OPTIONAL LEFT HAND RIGHT HAND optional standard Because the carriage tilt cylinder is used to tilt the bucket the carriage tilt lever is used to control the bucket Pull lever bac
37. and Maintenance Recommended Lubricants amp Capacities Torque Chart Boom INSPECTION AND MAINTENANCE LOG 18 0 HAND SIGNALS5 2 inside back cover GRADALL This Manual provides important information regarding safe operating and maintenance requirements for GRADALL Material Handlers Refer to front cover for specific model and serial number range 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 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 e Any optional equipment instructions furnished The operator must also read understand and comply with all applicable Employer Industry and Governm
38. arry position horizontal or below before leveling frame Attempting to level machine with boom raised could cause it to tip over 12 0 Rated Capacity Chart NOTE The rated capacity chart located on dashboard indicates maximum load See page 12 3 for instructions capacities for handlers equipped with GRADALL furnished carriage fork or other on how to read capacity charts attachment combinations These capacities apply to standard carriage fork and other attachment combinations except as stated on the capacity chart Figure 12 3 A WARNING GR AD ALL All loads shown on rated capacity chart are based on machine being on firm level ground the forks being positioned evenly on APACITY carriage the load being centered on forks proper size tires being properly inflated and the handler TS being in good operating condition 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 NOT EXCEED RATED LIFT CAPACITY LOADS AS UNSTABLE AND DANGEROUS MACHINE CONDITIONS WILL RESULT DONOT TIP THE MACHINE FORWARD TO DETERMINE ALLOWABLE LOAD CERTAIN CARRIAGEIFORK COMBINATIONS MAY CAUSE HANDLER TO TIP WITHOUT LOAD WHEN EXTENDED INTO NO OPERATION ZONE AS NOTED ON CAPACITY CHART merry sim
39. ases 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 SPECIFICATION CAPACITY P N 1440 4751 P N 1440 4595 0 5 qts gt EF 16 7 qts 15 8 L TORQUE lubricated ITEM FREQUENCY THREAD SIZE FT LB GRADE mum mamom won Boom Slide Bearings front 5 Weeks 250 hrs 3 8 24 5 32 37 43 50 5 Weeks 250 hrs 1 2 20 5 68 78 92 106 Boom Slide Bearings rear If front bearings have 3 8 24 5 32 37 43 50 worked loose 1 2 20 76 86 103 117 Boom Chain Jam Nuts Annually 1500 hrs 7 8 14 Cab Mounting Bolts upper Annually 1500 hrs 7 8 9 530 565 719 766 lower Annually 1500 hrs 3 4 10 340 365 461 495 Engine Assembly Flywheel Housing Bolts Annually 1500 hrs M10 40 45 54 61 Engine Mounts Annually 1500 hrs M12 66 76 89 103 M16 166 181 225 245 Front Axe Mounting Botts Annually 4500 hrs 3 4 10 hand hand Check torque at whichever interval occurs first 17 3 Checking amp Adjusting Boom Boom Bearing Pads Boom bearing pads are to be adjusted for all boom sections This should be done at boom assembly however some adjustments may be required after assembly e Add shims as required so that front and sides of boom have no more than 1 5mm 06 inch clearance e Add shims as required so that rear of boom has no more than 3 04mm 12
40. c performance This could cause unexpected machine movement After bringing the material handler to a stop using the service brake place the directional control lever in neutral and set the park brake prior to lifting a load Allow the handler to slow down or use the service brakes prior to down shifting Do not downshift more than one gear at a time When traveling on downhill slopes downshift to a lower gear and use the service brake as necessary to maintain a slow speed Do not shift into neutral and coast downhill Never permit diesel engine to run out of fuel Doing so can cause severe engine damage DO NOT burn or drill holes in forks Modifying any part of machine or attachment 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 lower forks to ground apply park brake move all controls to Neutral allow engine to run at low idle for 3 to 5 minutes Stop engine and remove ignition key Chock wheels
41. d with by all who operate this machine Strict attention to and compliance with instructions provided in this Manual the GRADALL Material Handler Safety Manual as well as instructional decals and plates affixed to the machine will help prevent injuries to personnel and damage to the equipment The information provided herein is not intended to cover all situations it is impossible to anticipate and evaluate all possible applications and methods of operation for this equipment This Manual covers recommended operating procedures and basic maintenance checks and services for the Material Handler Detailed maintenance information is available in the appropriate Service Manual Any procedure not specifically recommended by GRADALL must be thoroughly evaluated from the standpoint of safety before it is placed in practice If you are not sure contact your GRADALL Material Handler Distributor before operating Use only GRADALL authorized parts The use of counterfeit parts may cause premature failure which could lead to injuries and or machine damage Do not modify this machine without written permission from GRADALL Use only genuine GRADALL replacement parts OTHER NOTICES GRADALL retains all proprietary rights to the information contained in this Manual GRADALL reserves the right to change specifications without notice Gradall is a registered trademark for Hydraulic Excavators Hydraulic Material Handlers and Attachments manufactu
42. dall dealer for recommendations It is recommended that engine oil and filter transmission lubricant and filter transfer case lubricant and axle lubricant be changed after first 100 hours on new or rebuilt units 9147 3217 REVO Located on right cab wall P N 9147 3217 Form No 20036 G6 42A Owner Operator Manual 0 57201 06 9 10 GRADALL MATER MAX WEIGHT 2150 MEETS SAE J1040 MA MEETS ISO 3471 94 3 MEETS ANSI 56 6 8 16 GRADALL 9114 3261 SERIAL 8 Located on back wall behind operator s seat P N 9147 4483 enclosed cab P N 9147 4471 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 WORN WHILE OPERATING VEHICLE 000850 Located on left side front cab plate P N 9116 4094 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 boom head P N 9114 3290 Located on dash Starting S N 0160001283 P N 9141 3061 2 3 DECALS 4 WARNING DO GO NEAR LEAKS High pressure oil easily punctures s
43. ds to 1 turn Attention Do not exceed this value Form No 20036 G6 42A Owner Operator Manual The front axle service brakes will not operate when the park brakes are manually disengaged The rear brakes may only provide half of the machine s normal braking capability Always reset the brake release screws before allowing machine back in to regular service ADJUSTMENTS AFTER MANUAL RELEASE steps 4 6 Remove the screws 36 along with nuts 37 and seals Replace seals 39 lubricate screws 36 with silicone based TECNO LUBE 101 grease and re install the screws along with the nuts 5 Adjust jut of screw heads 36 in relation to the arm by 32 1 mm 6 Lock screws 36 in position with check nuts 37 Attention Check screw jut over with maximum care 16 2 GRADALL NOMENCLATURE Figure 17 1 Form No 20036 G6 42A Owner Operator Manual MAINTENANCE FRONT AXLE TIE DOWN LUGS SWAY CYLINDER HYDRAULIC TANK amp FILTER IMPLEMENT PUMP TRANSMISSION OIL FILTER ENGINE COMPARTMENT MIRROR BATTERY TRANSMISSION ENGI
44. e attachment he is using is listed at the bottom by part number He has determined the weight of the load to be lifted is 400 Ibs and that he needs to place the load at a boom extension of 6 at a boom angle of 20 By tracing the boom extension arc down to where the 20 line intersects it the contractor can see that the maximum weight he can lift is 600 Ibs In this case he may lift the load Figure 12 4 Where to look on the machine BOOM BOOM ANGLE EXTENSION INDICATOR NUMBER MACHINE SERIAL NUMBER PLATE RIGHT WALL FORK WEIGHT STAMP gt ATTACHMENT IDENTIFICATION PLATE 12 3 amp IR ANSYAUT Figure 12 5 Description of items a Capacity Chart NOTE This is a sample Capacity Chart ONLY Do not use this chart use the one located in your cab DEDUCT 350 LBS This ity Chart FROM ALL CAPACITIES ney with WHEN MACHINE IS this model ONLY EQUIPPED WITH WINCH 48 amp 72 SLOPE PILER Boom Extension Numbers Boom Angle 0 Regions indicate the maximum weight that may be lifted These numbers must match the Part No USE WITH stamped on the attachment 9140 5101 48 SLOPE PILER CARRIAGE 9140 5079 72 SLOPE PILER CARRIAGE ee Capacity Chart Part number Form No 20036 G6 42A Owner Operator Manual 1 2 a 4 ATTACHMENTS Approved Attachments Although the carria
45. e instrument panel A variable speed defroster fan is available for use with enclosed cabs An On Off control switch and speed control are located on the base of the fan 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 an S A E FOPS ROPS structure Do not make any modification to this structure If damaged the cab cannot be repaired It must be replaced CONTROL AND INSTRUMENT IDENTIFICATION Figure 3 1 LEVEL INDICATOR TRANSMISSION TEMPERATURE WARNING LIGHT TRANSMISSION CONTROL LEVER FORWARD REVERSE GEAR CHANGE LEVER AUX CONTROL LEVER OPTIONAL HOURMETER STEERING WHEEL PARK BRAKE OIL PRESSURE COOLANT TEMP VOLTMETER FUEL GAUGE HORN BUTTON CAPACITY CHARTS BOOM CONTROL JOYSTICK IGNITION SWITCH S N 0190001 thru 0160001277 IGNITION SWITCH S N 0160001283 thru Current BRAKE PEDAL STEER SELECT SWITCH Form No 20036 G6 42A Owner Operator Manual ACCELERATOR PEDAL OPERATOR S CAB 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 c
46. ected again the transmission will go back to fourth gear Form No 20036 G6 42A Owner Operator Manual DRIVE TRAIN Bring handler to a complete stop before shifting transmission control lever A sudden change in direction of travel could reduce stability and or cause load to shift or fall 10 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 A WARNING frame to permit operator to determine whether the handler frame is level E Raising the boom loaded or unloaded when handler is leaning to one side could cause machine to tip over with little or 1 Never engage a load or lift a load more than 1 2m four feet above no warning and cause serious ground unless handler is level injury or death There are four very important things to remember about handler leveling 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 1 2m 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 1 2m 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
47. 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 6m 24 inches from front vertical face of forks 1 0 WATCH FOR THESE SYMBOLS THEY CALL YOUR ATTENTION TO SAFETY NOTICES DANGER gt This symbol indicates extreme hazard which will result in high probability of death or serious injury if proper precautions are not taken This symbol indicates a hazard which could result in death or serious injury if proper precautions are not 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 transmission control lever in Neutral position parking brake applied and all hydraulic controls in Neutral before starting engine GRADALL Release trapped pressure before disconnecting opening or removing any hydraulic component Keep all windows and mirror s clean Adjust mirror s as required for maximum visibility before and during operation Do not increase engine speed with the transmission in forward or reverse and the service brake pedal depressed in an attempt to get quicker hydrauli
48. ental rules standards and regulations Orientation When used to describe the location of components in the material handler the directions front rear right and left relate to the orientation of a person sitting in the operator s seat See figure I 1 Related Manuals amp Decals Separate publications are furnished with the material handler to provide information concerning safety replacement parts maintenance procedures theory of operation and vendor components Replacement manuals decals and instruction plates can be ordered from your GRADALL Material Handler Distributor Models Covered This Manual covers basic information for Gradall Material Handlers Detailed information for each particular machine is in the maintenance section in the back of this manual Be certain to refer to proper information for your unit and the optional 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 INTRODUCTION NOTE Material handler and handler are used interchangeably throughout this Manual NOTE Though no offense or discrimination is intended only the masculine pronouns will be used throughout the remainder of this Manual NOTE In the U S A the op
49. er boom to position load 1 2m 4 feet or less above ground allowing for best visibility e Use mast as required to increase vertical reach of handler e Use a signal man to assist in positioning the load if necessary Swing Forks Capacity Maximum lift capacity for swing forks is shown on the attachment capacity chart However maximum lift capacity applies only to certain areas within boom extension elevation pattern of handler swing forks combination A separate capacity chart must be used for handlers equipped with swing forks Study and understand this chart before attempting to handle a load with swing forks attachment Form No 20036 G6 42A Owner Operator Manual PRECAUTIONS Read additional capacity information under Capacity heading e Because the mast increases lift height it isespecially important to level the handler before lifting a load more than 1 2m four feet above ground See 11 0 Do not handle a load with Mast attachment until you study and understand the Mast Capacity Chart If your handler does not have a Mast Capacity Chart ask your supervisor to get one before using the attachment Do not handle a load with Swing Forks attachment until you study and understand the Swing Forks Capacity Chart If your handler does not have a Swing Forks Capacity Chart ask your supervisor to get one before using the attachment 13 3 Attachment Tilt Controls
50. erator must have completed a training course meeting the OSHA Powered Industrial Truck Operator Training Requirements CFR 1910 178 LEFT lj IlH5IW REAR Figure I 1 AD MODEL mace SERIAL 0 ENGINE SERIAL NO 19430 LES 66 424 Figure I 2 Form No 20036 G6 42A Owner Operator Manual SAFETY HIGHLIGHTS Read and understand all manuals and instructional material listed on cover inside front cover and introduction page of this Manual before starting operating or performing maintenance procedures on this equipment Regardless of previous experience operating similar equipment the operator must be given sufficient opportunity to practice with the handler in a safe open area not hazardous to people or property to gain operating skills and the proper feel for controls and operating clearances required for safe efficient operation GRADALL Material Handlers are equipped with a right side rearview mirror This mirror is intended as an operator s aid and does not replace the requirement for line of sight Certain job site and machine conditions may require use of a signal person to help the operator when picking placing or transporting a load Never operate the handler until you know pick up point line of travel and landing point
51. ge 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 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 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 combi
52. heater defroster etc are turned off Set parking brake 2 Depress accelerator pedal approximately 1 4 to 1 3 of travel from top 3 Turn ignition switch to START to engage starting motor Release key immediately when engine starts If engine fails to start within 20 seconds release key and allow starting motor to cool for a few minutes before trying again 4 After engine starts observe oil pressure gauge If gauge remains on zero for more than ten seconds stop engine and determine cause Correct malfunction before restarting engine Minimum pressure at operating temperature Low idle 10 PSI 69kPa 5 Warm up engine at approximately 1 2 throttle until engine coolant temperature reaches operating range Cold Weather Starting Aids In cold weather situations a supplemental starting aid may be required Gradall approved starting aids employ ether If your handler is equipped with an ether starting aid the following applies All employed ether 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
53. igned to carry a maximum of 3 occupants The load includes personnel materials tools etc The maximum capacity of your work platform is based on specific model material handler work platform combination To determine maximum load capacity for given operating ranges consult the proper load capacity chart furnished with platform for the material handler and work platform in use If your handler is not equipped with the proper personnel work platform capacity chart get one before using the attachment Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See page 13 1 Operation e Gradall Personnel Work Platforms are approved for use only on Gradall Material Handlers equipped with the proper platform capacity chart e When lifting personnel use only a Gradall manufactured personnel work platform No other platform is approved for use on Gradall Material Handlers 13 8 Do not use the Personnel Work Platform until you study amp understand the Capacity Chart If your handler does not have the correct Personnel Work Platform Capacity Chart ask your supervisor to get one before using the attachment Do not use a boom mounted winch while the platform is mounted to the boom GRADALL OBTAINING HYDRAULIC OIL SAMPLE 1 Operate unit until hydraulic oil reaches normal operating temperature 2 Apply parking brake lower boom to rest and shift Forward Reverse lever to NOTE
54. in and refill HF 2 20 Special engine break in oil drain amp refill replace filter EO 1 35 Planetary Drain Plugs drain while draining differential HF 4 15 Transmission Oil amp Filter drain amp refill replace filter HF 1 At End of First 30 Days Only 250 Hours Maximum Lubrication amp Maintenance Check torque of all items listed in Torque Chart pg 17 3 Lube No of Symbol Points 5 Week or 250 Hour Lubrication amp Maintenance include all previous periodic services 1 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 2 Boom Rear Slide Bearings lube paths HM 3 Boom Extend Chain check adjustment and adjust as required 5 Boom Front 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 3mm 1 8 inch shim or replace as required when these bearings require service check all other slide bearings shims are 1 5mm 1 16 inch thick 6 Axle Kingpins HM 7 Axle Level Plug check level and refill as required HF 8 Axle Trunnions HM 20 Engine Crankcase Filler Cap drain oil and refill top level EO 21 Engine Oil Filter replace filter element 23 Drive belts check condition replace as required 27 Drive Shaft Slip Joints HM 29 Vacua
55. inch total clearance e Number of shims at each pad may vary however shims at bottom front pads must not vary more than one shim between sides e 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 B Tighten adjusting nut on extend chain rod until all washers are just flat no gap between any washers Torque lock nut to 100 ft Ib 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 chain lock nut and adjusting nut Tighten retract chain adjusting nut until proper distance between 2 and 3 boom sections and proper access hole alignment is obtained Torque lock nut to 100 ft Ib Adjust extend chain per instructions above mo o Om For more
56. ine at low idle Check in each steering mode 12 Horn and back up alarm Must be audible from inside operators cab with engine running 13 All boom and attachment functions operate smoothly and correctly 14 Hydraulic Filter Condition Indicator observe engine coolant temperature gauge after starting normal operation When needle has been in operating range for an hour or so stop handler in a safe area apply parking brake lower forks fully shift forward reverse lever to Neutral position and chock wheels With engine running at full throttle have an assistant 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 needle reaches red area Complete all required maintenance before operating unit Form No 20036 G6 42A Owner Operator Manual Check all tires and rims periodically for damage due to impact Replace before use if damage is detected CAUTION Keep engine cover closed while engine is running except when checking Transmission Oil Level and hydraulic filter condition indicator Continued operation with hydraulic fluid bypassing the filter may cause severe damage to hydraulic system components 5 0 Starting the Engine 1 Make sure all controls are in Neutral and all electrical components lights
57. ing a spotter load the handler with boom as low as possible to keep a low center of gravity 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 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 Do not tie down front of boom Figure 15 1 front view Figure 15 2 rear view 15 0 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 GRADALL 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 steering system permits manual steering if engine or power assist feature fails Remember e Although manual steering is possible without power assist steering will be slow and will require much greater force e Response to manual steering will be i
58. ion elevation pattern of handler truss boom combination A separate capacity chart must be used for handlers equipped with truss boom Study and understand this chart before attempting to handle a load with truss boom Observe the following Special Precautions e Never drag the load lift vertically e Use tag line to guide and steady a suspended load Tag lines must be long enough to keep helpers clear of load and handler e Beware of wind Wind can cause a suspended cause dangerous side loads even with tag lines load to swing and 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 e Do not attempt to use handler frame leveling to compensate for load swing Attachment Tilt Controls Figure 13 7 LOWER WINCH LOAD The carriage tilt cylinder is used to tilt the AUXILIARY truss boom up and down from the handler CONTROL LEVER RAISE boom head The carriage tilt lever controls WINCH truss boom tilt 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 head See page 13 1 other attachment from boom 2 Install truss boom on boom head Operation e If truss boom winch is furnished connect auxiliary hydraulic hoses to winch e Approach truss or truss bund
59. k to raise bucket lip push lever forward to lower bucket lip Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See page 13 1 2 Install light material bucket on boom head 3 Retract boom fully and tilt bucket up or down as required to position bottom of bucket parallel with ground 13 2 PRECAUTIONS e Always adjust fork position before engaging load As with all other attachments handler must be level before handling a load more than 1 2m four feet above ground level See Leveling The Handler page 11 0 Observe all precautions and load capacity limits listed previously when handling loads with carriage fork positioner PRECAUTIONS e Handler must be level before handling a load more than 1 2m four feet above ground level See page 11 0 e Retract boom fully before loading bucket Loading bucket with boom extended could damage structural members or extension chains cables e Avoid shock loads drive into stockpile smoothly to load bucket Do not use bucket as a lever to pry heavy material Excessive prying forces could damage the bucket Do not use bucket for back dragging This could cause severe damage to Quick Switch fittings A WARNING Observe all precautions and load capacity limits listed previously when handling loads with light material bucket C e os LT Operation e Raise or lower boom to appropriate height for
60. kin causing serious injury gangrene or death If injured seek emergency medical help Immediate surgery is required to remove A Do not use finger or skin to check for leaks Lower load or relieve hydraulic pressure before loosening fittings 1995 Signa Tek Inc Located on frame beside main control valve P N 9108 3492 GRADALL Genuine Parts HYDRAULIC SYSTEM FILL WITH TRACTOR HYDRAULIC FLUID Mobilfluid 424 or equivalent For Mobil Product Information Call 1 800 662 4525 9114 3288 Located on hydraulic reservoir P N 9114 3288 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
61. l circle with forefinger pointing horizontally at open hand RAISE BOOM With either arm ex tended horizontally fingers closed point thumb upward LOWER BOOM With either arm extended horizontally fingers closed point thumb downward TILT FORKS UP With one arm held TILT FORKS DOWN With one arm at side extend other arm upward held at side extend other arm at about 45 downward at about 45 MOVE SLOWLY Place one hand motionless in front of hand giving THIS FAR TO GO With hands raised motion signal Raise load slowly is and open inward move hands shown laterally indicating distance to go STOP ENGINE Draw thumb or forefinger across throat Form No 20036 G6 42A Owner Operator Manual CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm CALIFORNIA Proposition 65 Warning 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 406 Mill Ave SW New Philadelphia Ohio USA 44663 Phone 330 339 2211 Fax 330 339 8468 http www gradall com Printed in USA
62. le 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 13 6 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 11 0 e Travel with load and boom lowered to travel position 1 2m 4 feet or less above ground e Always lower load to rest before leaving handler Do not handle a load with Truss Boom amp Truss Boom with Winch attachment until you study and understand the Truss Boom amp Truss Boom with Winch Capacity Chart If your handler does not have a Truss Boom amp Truss Boom with Winch Capacity Chart ask your supervisor to get one before using the attachment A side load or a swinging load could cause the handler to tip over and or damage the boom GRADALL e Open clamps at heel of truss boom far enough to clear load and tilt truss boom up until truss bundle contacts heel of truss boom e Close clamps to hold load lightly and secure clamps e Transport load to delivery site and attach tag lines if load will be freely suspended Swing Mast Capacity Maximum lift capacity is shown on attachme
63. lever It is best to begin travel in a lower gear however the machine will move away from rest in any gear Upshifts are most smoothly accomplished by lifting off the throttle pedal when shifting Caution should be taken of downshifting to ensure that the ground speed of the material handler has slowed sufficiently so as not to over speed the engine Select the appropriate gear for the task being performed Use a lower gear when transporting a load Use a higher gear only when traveling longer distances without a load When traveling through deep mud or up slopes use a lower gear Downshift a gear when traveling down a long hill Use the service brakes if necessary to prevent over speeding the engine Direction of Travel Direction of travel is selected by moving the transmission control lever towards the front of the machine for forward travel and towards the rear of the machine for reverse travel Neutral is selected by moving the transmission control lever to the center position If neutral is selected while the machine is moving the machine will continue rolling in the direction of travel Always bring the machine to a complete stop before changing direction of travel This will prevent damage to the transmission or torque converter Forward or reverse travel can be selected while in any gear With turbocharged engine if reverse is selected while in fourth gear the transmission will automatically default to third gear If forward is sel
64. llustrated Figure 12 1 LOWER LOWER amp BOOM LOWER amp RETRACT EXTEND BOOM BOOM RETRACT EXTEND BOOM BOOM RAISE amp lt Sel se amp RETRACT EXTEND BOOM BOOM FRONT OF MACHINE RAISE 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 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 12 2 TILT TILT TILT FORKS DOWN DOWN UP DOWN TILT TILT FORKS FORKS UP UP LEFT HAND RIGHT HAND OPTIONAL optional standard Form No 20036 G6 42A Owner Operator Manual NOTE Much of the material in this section may be new to even the experienced operator Do not permit lift cylinders to hit the end of their stroke The jolt could topple loads causing a hazard to personnel and equipment nearby Always move boom to c
65. loading material from stockpile e Align handler with face of stockpile and drive slowly and smoothly into pile to load bucket Do not corner load bucket e Tilt bucket up far enough to retain load and back away from pile e Lower bucket to carry position 1 2m 4 feet or less above ground and travel carefully to unloading point Turn bucket down to dump load Mast 1 8m 6 with 1 2m 4 or 1 8m 6 carriage Capacity Maximum lift capacity indicated on attachment serial number plate applies only to certain areas within boom extension elevation pattern of handler mast combination A separate capacity chart must be used for handlers equipped with mast Study and understand this chart before attempting to handle a load with mast attachment Attachment Tilt Controls Figure 13 3 LOWER Q FORKS The 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 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 13 1 2 Install mast on boom head 3 Connect auxiliary hydraulic hoses to mast cylinder Operation e Always level handler before raising the boom or the forks with or without a load e To travel with a load lower forks fully in mast and low
66. m in air If parking on a slope cannot be avoided position the handler at a right angle across the slope straighten and chock all wheels Parking procedure 1 2 3 Form No 20036 G6 42A Owner Operator Manual Using service brake stop the handler in an appropriate parking area Shift transmission control lever to Neutral Move parking brake switch to On Position attachment on ground Allow engine to cool at idle speed for 3 to 5 minutes stop engine and remove ignition key Chock wheels as an extra precaution against rolling Fill fuel tank to minimize condensation Lock cab and install protective covers if so equipped Disconnect battery if unit is in an area where tampering is a risk 8 0 STEERING SYSTEM e Three modes of steering are provided as standard equipment A three position switch on the dashboard allows the operator to select the steering mode e 4 wheel circle steer allows for tight turns and better maneuverability in close quarters e 4 wheel crab steering allows the machine to move sideways at an angle and is used to position the machine e 2 wheel front steer is used for high speed travel An optional fourth mode is available which allows for 2 wheel rear steering A two position switch on the dash allows the operator to select front or rear steering when in the 2 wheel steer mode This mode can be used for easier positioning of the machine when picking up a lo
67. ms needed to Use a Capacity Chart There are five items you must know and or have in order to properly use a Capacity Chart 1 The weight of the load to be lifted 2 The angle of the boom 3 How much boom extension will be needed 4 The proper Capacity Chart 5 A Gradall approved Attachment Every Gradall attachment comes with its own Identification Plate This Plate has the Attachment Serial Number Part Number Attachment Capacity and Attachment Weight stamped on it Make sure that the Capacity Chart you are using matches the attachment exactly This may be done by matching the attachment part number on the Capacity Chart to the part number stamped on the Identification Plate The Machine Serial Number Plate is mounted inside the cab and lists all standard attachments that may be used with the machine by part number at the time it was shipped from the factory Be aware that a specific Capacity Chart must not only match the attachment but also the machine model The boom angle can be determined by looking at the angle indicator mounted on the side of the boom See figure 12 4 The boom extension can be determined by looking at the second boom section As the second boom section slides out of the main boom numbers are revealed starting with 1 Each number represents approximately 5 feet of total boom extension See figure 12 4 It is important to remember that these numbers are designed to be read from the operator s seat only Form
68. n 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 e TT G FADO AL Load Center Loads shown on rated capacity chart are based on the load center being 610mm two feet above and 610mm two feet 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 possible In all cases the load center must be centered between the forks Load Limits Some capacities shown on the rated capacity chart are based on machine stability and some are based on hydraulic lift capacity The common sense or feel an experienced operator might apply in regard to tipping loads DOES NOT APPLY to hydraulic load limits Exceeding load limits can cause damage or in some cases cause the machine to tip over Ite
69. nations 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 Distributor to determine capacity limitations Other Attachment Capacities A serial number capacity plate is attached to all GRADALL furnished attachments Do not assume that any GRADALL attachment may be used on any GRADALL Material Handler First check the listing of approved attachments on handler serial number plate If the attachment in question is not included in the list contact your local GRADALL Distributor to check whether or not the attachment is approved Next if the attachment is approved for use with your handler compare maximum capacity from attachment serial number plate and value stamped on forks to maximum capacity for that attachment as indicated on material handler serial number plate The smallest of these values is correct for your handler 13 0 Attachments which have not been appro
70. ncreased 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 30m 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 30m 100 feet but less than 182m 200 yards it is permissible to use a vehicle of sufficient capacity to tow unit after you e Release parking brake See pages 16 1 amp 16 2 MOVING LONGER DISTANCES If the handler must be moved more than 182m 200 yards it must be loaded on to a trailer of sufficient capacity Form No 20036 G6 42A Owner Operator Manual 16 0 RELEASE PARKING BRAKE CARRARO AXLE 1 If possible position unit on level ground lower attachment to approximately 3m one foot from ground move forward reverse lever to Neutral apply Jf you release the park brake rkin rake an t engine without first blocking the wheels g bra and stop gine the material handler could roll Block all wheels before releasing 2 Block all wheels to prevent inadvertent movement park brake RELEASE Figure 16 1 SCREW 12 o clock position FRONT OF HACIENDO M RELEASE SCREW 4 o clock position 8 o clock position 3 Working one side at a time remove three plugs from differential housing located at 12 o clock
71. nt serial number plate However maximum lift capacity applies only to certain areas within boom extension elevation pattern of handler swing mast combination A separate capacity chart must be used for handlers equipped with mast Study and understand this chart before attempting to handle a load with swing mast attachment Controls Figure 13 8 SIDE SHIFT The carriage tilt cylinder is used to tilt the mast and the carriage Tilt lever controls mast tilt SWING MAST e Press right switch up to SIDE SHIFT to activate side shift function Move auxiliary hydraulic lever in appropriate direction 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 13 1 2 Install swing mast on boom head and connect auxiliary hydraulic hoses to swing mast diversion valve hoses Also connect electrical cable at boom head Operation e Always lower carriage fully in mast and position forks straight ahead before engaging load e To travel with a load keep forks straight ahead and lower load to travel position 1 2m 4 feet or less above ground e Inspect supporting surface at delivery point and have it leveled if necessary e Level handler before raising load
72. 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 GRADALL WARM UP amp OPERATIONAL CHECKS To be performed at beginning of each work shift The safety efficiency and service life of your handler will be increased by performing the operational checks listed below Items preceded by an asterisk are optional and may not be furnished on your machine Before entering the operator s cab check 1 Engine oil level 2 Filter Restriction Indicator If needle is in red area filter is clogged and element must be cleaned or changed During warm up period check 3 Heater defroster and windshield wiper 4 Hydraulic oil level 5 Operating lights and rotating beacon 6 Voltmeter should show 13 5 to 14 volts When engine warms to operating range check 7 Transmission fluid level 8 Service brake and parking brake 9 Forward and reverse travel 10 Each of the gear ranges 11 Steering stop to stop in both directions with eng
73. red by The Gradall Company GRAIDALL REVISIONS This page is provided so you may determine that this Manual is complete and current with respect to Gradall Engineering Specifications Page 7 22 02 Added an additional lubrication notice sss Revs nos emen O revise 9147 9323 with 9147 3217 De sed eines haus im beat Trevis ications on 8108 3952 91 3200 NM beak revised opertors ab seston a Figure Sh ees senes sedeo OOO sorina nasen O revised service sate secon OOOO rerea precaution Posing Previa and seenen removet rowe eemermwe rs ses O revise personne wore pwone fried morma OOOO na carare Ante changed chook Mocks 17 0 Added Figure 17 1 17 1 Revised art Changed Carraro Axle Values amp Added Dana Axle Values N w Form No 20036 G6 42A Owner Operator Manual TABLE OF CONTENTS IMPORTANT SAFETY NOTICE inside front cover TABLE OF CONTENTS INTRODUCTION General Operator Qualifications Orientation Related Manuals amp Decals Models Covered Serial Number Location SAFETY AIG HLIGHTS REB REA T ei wasn ba aetna are 1 0 pl ie b 2
74. rmal operating temperature and engine running at full throttle replace filter element before by pass indication is reached or at least annually 1 15 Transmission Fluid Level HF 1 18 Hydraulic Level Sight Gauges level handler retract all other cylinders and check sight gauges refill as required HF 1 19 Engine Crankcase Dipstick level handler and check fluid level refill as required EO 1 30 Fuel Filler Cap fill at end of work shift to minimize condensation DF 1 Weekly or 50 Hour Lubrication amp Maintenance include all previous periodic services 4 Extend Retract Chain Sheaves HM 3 5 Boom Bottom Front Slide Bearings extend boom fully and lube all wear paths retract and extend boom fully three times and wipe excess lube from bearings HM 4 11 Sway Cylinder Pivots HM 2 14 Battery check terminals 1 22 Fuel Filter Water Separator with Drain replace element 1 24 Radiator Fill Cap check level and refill as required refer to John Deere Manual for coolant conditioner ratio 1 28 Boom Lift Cylinder Pivots HM 2 31 Tires check for damage and proper inflation 13 00 x 24 12 ply 445 kpa 65 psi 13R24 12 Ply 482 kpa 70 psi 15 5 25 12 400 kpa 58 psi 4 32 Boom Pivots HM 2 33 Compensating Cylinder Pivots HM 2 37 Carriage Tilt Cylinder Pivots HM 2 38 Boom Head Carriage Pivot HM 2 39 Quick Switch Latch HM 1 At End of First 50 Hours Only 10 Differential Drain Plug dra
75. s engine oil pressure Fuel Gauge This gauge displays level of fuel in fuel tank Heater Fan Switch optional This switch turns heater fan on and off DEFROSTER FAN TEMPERATURE CONTROL HEATER FAN SWITCH ACCESS COVER HEATER VENT Hourmeter This meter indicates total time of engine operation in hours and tenths of hours Ignition Switch This switch is actuated by a key In ACC or RUN position voltage is available for all electrical functions Full clockwise rotation to START engages starter motor Counter clockwise rotation to OFF stops engine and removes voltage from 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 3 Tc GRAD ALI 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 Neutral Lock Lever The transmission control switch is equipped with a lever that locks the transmission in neutral when activated 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 Seat lock Release Lever This lever unlocks and locks seat position adjustmen
76. t Service Brake The further the pedal is depressed the slower the travel speed Full depression of pedal causes full service brake application Steer Select Switch This switch has three positions to allow selection of 4 wheel circle steer 4 wheel crab steer and 2 wheel steer 4 wheel circle steer allows the front and rear wheels to steer in opposite directions for tight turns 4 wheel crab steering turns the front and rear tires in the same direction for moving the machine to the side 2 wheel steer allows only the front wheels to steer Steering Wheel The steering wheel controls the angle of wheels Turning the steering wheel to the right causes a right turn Turning the steering wheel to the left causes a left turn Transmission Control This lever engages forward or reverse travel Push lever fully forward for forward travel pull lever fully backward for reverse travel Move lever to centered position for Neutral Twist hand grip for 1st 2nd 3rd and optional 4th forward only gear Transmission Temperature Light This light will illuminate during starting procedure for a bulb check If transmission temperature exceeds 250 light will glow indicating the need for service Voltmeter This gauge indicates alternator output and battery condition Form No 20036 G6 42A Owner Operator Manual 2 Wheel Front Steer If transmission temperature light glows move material handler to a safe
77. th 5 Secure lock 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 special attention to capacity and range limits for the handler attachment combination Practice operation of handler and attachment in a safe open area not hazardous to yourself other persons equipment or property Become thoroughly familiar with response of handler and attachment to controls before operating in a work situation Always consider terrain between present location of load and delivery point Never attempt to transport a load across terrain which could cause handler to tip over 13 1 Form No 20036 G6 42A Owner Operator Manual Fork Positioner Capacity Maximum load capacity for fork positioner carriage is the s
78. 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 6 0 Operator must be seated with seat belt fastened transmission control 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 transmission control lever is in Neutral and parking brake switch is applied If your machine is equipped with a cold start aid do not spray additional ether into air cleaner If machine is not equipped with cold start aid follow instructions listed in the engine manual supplied with machine GRADALL 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
79. tor Valve rubber cone on bottom check to be sure cone is clear and undamaged 35 Planetary Level Plug HF 36 Transfer Case check and top off HF 12 12 m PAR e Check torque of all items listed in Torque Chart pg 17 3 Quarterly or 500 Hour Lubrication amp Maintenance include all previous periodic services 16 Hydraulic System we recommend that hydraulic fluid be analyzed to determine condition drain and refill reservoir if required HF 17 Hydraulic Reservoir Screen remove clean and install when hydraulic oil is drained 22 Fuel Filter Water Separator with Drain replace element Semi Annual 1000 Hour Lubrication amp Maintenance include all previous periodic services 9 Hyd Tank Filter Breather replace 10 Axle Drain Plug drain and refill HF 15 Transmission Drain Plug drain fill to level replace filter HF 32 Rear Hub Drain Plug drain and refill HF 35 Planetary Drain Plugs drain while draining differential HF 36 Transfer Case drain amp refill Annual or 1500 Hour Lubrication amp Maintenance include all previous periodic services 13 Hydraulic Return Filter replace filter element 16 Hydraulic System unless fluid is analyzed quarterly to determine degree of contamination reservoir must be drained and refilled on an annual basis HF 17 Hydraulic Reservoir Screen remove clean and install when hydraulic oil is drained 24 Engine
80. ved 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 on the handler GRADALL Attachment Installation This installation procedure is designed for one man operation If a helper is involved shut off the engine before proceeding to steps 4 and 5 4 amp t Eo 9 1 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 out position with retainer pin M LU 3 Engage Quick Switch attachment 4 Remove retainer pin and slide lock tilt lever backward pin in fully Always be certain that carriage or attachment is properly positioned on boom head and is secured by lock pin and retainer pin Failure to ensure proper installation could permit carriage attachment load to disengage and cause serious so az injury or dea

Operation 91474003

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