Gradall 534D-10 Operation Manual

Name: Gradall 534D-10
Brand: Gradall
SKU: 1589510
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534D-9

534D-10

9134-4052

January 11, 2007

534D-9 Starting Serial No.

0544001 thru 0744407

& 0160000112 thru 0160003965

534D-10 Starting Serial No.

0366001 thru 0366533

& 0160000125 thru 0160003965

OWNER/OPERATOR MANUAL

CORPORATE OFFICE

JLG INDUSTRIES, INC.

1 JLG DRIVE

McConnellsburg, PA

17233-9533

USA

Telephone: (717) 485-5161

Fax: (717) 485-6417

GRADALL DIVISION

JLG INDUSTRIES, INC.

406 Mill Avenue S.W.

New Philadelphia, OH

44663

USA

Telephone: (330) 339-2211

Fax: (330) 339-8458

Form #20219 Original Issue 6/03

A Company

COVERING OPERATION & PERIODIC MAINTENANCE

534D-9/534D-10

MATERIAL HANDLER

OWNER/OPERATOR MANUAL

KEEP OPERATOR AND SAFETY MANUALS IN CAB

Part No. 9134-4052

Revised 01-11-07

Form No. 20219

COVERS MATERIAL HANDLERS 534D-9 & 534D-10

STARTING SERIAL NUMBERS

534D-9 0544001 thru 0744407 and

0160000112 thru 0160003965

534D-10 0366001 thru 0366533 and

0160000125 thru 0160003965

IMPORTANT!

Read and understand this Manual and the Gradall Material

Handler Safety Manual before starting, operating or

performing maintenance procedures on this machine.

material handler

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IMPORTANT SAFETY NOTICE

Safe operation depends on reliable equipment and proper operating procedures.

Performing the checks and services described in this Manual will help keep your GRADALL

Material Handler in reliable condition. Following recommended operating procedures

can help you avoid accidents. Because some procedures may be new to even the

experienced operator, we require that this Manual be read, understood and complied

with by all who operate this machine.

Strict attention to and compliance with instructions provided in this Manual, the GRADALL

Material Handler Safety Manual, as well as instructional decals and plates affixed to

the machine will help prevent injuries to personnel and damage to the equipment. The

information provided herein is not intended to cover all situations; 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 manufactured by The Gradall Company.

Form No. 20219

534D-9/534D-10 Owner/Operator Manual

REVISIONS

This page is provided so you may determine that this Manual is complete and current with respect to Gradall

Engineering Specifications.

Page Date Revision

6/03 Original Issue, replaces Owner/Op Manual 9134-4051 (Form #20046).

Cover 01/07 Revised ending serial numbers.

IMPORTANT SAFETY NOTICE ..................................................... inside front cover

TABLE OF CONTENTS

INTRODUCTION

General

Operator Qualifications

Orientation

Related Manuals & Decals

Serial Number Location

NOMENCLATURE

SAFETY HIGHLIGHTS ............................................................... 1.0

DECALS ................................................................................. 2.0

Decals Inside Cab

Decals Outside Cab

OPERATORS CAB ..................................................................... 3.0

Cab

Control & Instrument Identification

CHECKS & SERVICES BEFORE STARTING ENGINE ....................... 4.0

WARM-UP & OPERATIONAL CHECKS .......................................... 5.0

ENGINE OPERATION ................................................................ 6.0

Starting the Engine

Cold-Weather Starting Aids

Battery-Boosted Starting

Normal Engine Operation

Stopping the Engine

John Deere Engine Shut-Down Protection Feature

BRAKE SYSTEM ....................................................................... 7.0

General

Inching Travel

Service Brakes

Parking Brakes

PARKING THE HANDLER........................................................... 8.0

STEERING SYSTEM .................................................................. 9.0

DRIVE TRAIN .......................................................................... 10.0

LEVELING THE HANDLER ......................................................... 11.0

OPERATING PROCEDURE & TECHNIQUES ................................... 12.0

Hydraulic Controls

Rated Capacity Chart

ATTACHMENTS ........................................................................ 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 & SECURING FOR TRANSPORT .................................... 15.0

MOVING HANDLER IN EMERGENCY............................................ 16.0

Moving Short Distances

Moving Longer Distances

To Activate Tow Bypass

To Release Parking Brake

To Restore Parking Brake

MAINTENANCE SECTION .......................................................... 17.0

Nomenclature

Lubrication and Maintenance

Lubrication Chart

Torque Chart

Boom

Stabilizer

INSPECTION AND MAINTENANCE LOG ....................................... 18.0

HAND SIGNALS ....................................................................... inside back cover

Form No. 20219

534D-9/534D-10 Owner/Operator Manual

General

This Manual provides important information regarding safe operating and

maintenance requirements for GRADALL Material Handlers.

If you have any questions regarding the material handler, contact your GRADALL

Material Handler Distributor.

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 in the safe operation of this type of material handling

equipment.

In addition, the operator must read/view, understand and comply with

instructions contained in the following material furnished with the material

handler:

• This Owner/Operator Manual

• GRADALL Material Handler Safety Manual

• All warning and instructional decals and plates

• Any optional equipment instructions furnished

The operator must also read, understand and comply with all applicable

Employer, Industry and Governmental rules, standards and 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 & 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 operational equipment furnished on your machine.

Serial Number Location

Specify Model Number and Serial Number when ordering parts and when

discussing specific applications and procedures with your Distributor. The model/

serial number plate is located inside the operator’s cab, right wall.

(See Figure I-2)

NOTE!

“Material handler” and handler are

used interchangeably throughout

this Manual.

Though no offense or

discrimination is intended, only

the masculine pronouns will be

used throughout the remainder of

this Manual.

NOTE!

REAR

FRONT

RIGHT

LEFT

Figure I-1

Figure I-2

INTRODUCTION

TRUSS BOOM

P/N 9045-5011

24,180

TRUSS BOOM W/WINCH

P/N 9045-5012

24,420

26,190

26,450

6' MAST W/48" CARR

P/N 9045-5035

25,380

6' MAST W/66" CARR

P/N 9045-5037

25,460

72" 100° SWING CARR

P/N 9045-5044

25,160

48" SLOPE PILER

P/N 9108-5058

24,630

66" SLOPE PILER

P/N 9130-5016

24,750

6' SW. MAST W/48" FORKS

P/N 9045-5047

6' SW. MAST W/60" FORKS

P/N 9045-5054

1.6

--- ---

24 24

3.7

8.7

-.7

-1.6

WORK PLATFORM

P/N 9055-5024

2.7

24,520

24,040

-.9

4.5

24,220

2.3

24,540

24 24

AS RELEASED FROM FACTORY THIS TRUCK MEETS THE DESIGN SPECIFICATIONS

ATTACHMENT

DCBA

24,420

9134-3062 (REV. D)

(WITHOUT

ATTACHMENTS)

36 40

24 24

-.9

23,570 LBS

36 24 24

-.9

24 24

45 --- ---

24,320

--- ---

III

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.

ESTABLISHED IN AMERICAN NATIONAL STANDARDS FOR POWERED INDUSTRIAL

TRUCKS PART ASME B56.6b-1998.

CAPACITY WITH STANDARD

48", 66", & 72" CARRIAGE

CAP#

1000

TRUCK &

ATTACHMENT

WEIGHT

SHIPPED

WITH

CAP#

X1000

*WEIGHTS ARE BASED ON USING 1 3/4 X 6 X 48" FORKS (APPROX. 356# PER PAIR)

**BUCKET DIMENSIONS (A & D) REFER TO BUCKET LIP HEIGHT.

***TRUSS BOOM, WINCH & QUICK HOOK DIMENSIONS (A & D) REFER TO HOOK CENTER.

****WEIGHT IS BASED ON SP'L SWING MAST FORKS (48": APPROX. 220# PER PAIR)

(60": APPROX. 490# PER PAIR)

*****PLATFORM DIMENSIONS (A & D) REFER TO CENTER OF FLOOR.

48" CARRIAGE

P/N 9045-5051

66" CARRIAGE

P/N 9045-5052

72" CARRIAGE

P/N 9055-5008

3/4 YD BUCKET

P/N 9045-5049

1 1/4 YD BUCKET

P/N 9055-5020

534D9-45

GRADALL IS A REGISTERED TRADEMARK

FOR HYDRAULIC EQUIPMENT

BUILT BY THE JLG COMPANY

1 JLG DRIVE, McCONNELLSBURG, PA.

U.S.A.

****

***

****

FT IN IN

IN IN

FT FT

IN IN

SAM

PLE O

NLY - USE CHART IN CAB

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.

Operators of this equipment must have successfully completed a training course

in the safe operation of this type of material handling equipment.

Regardless of previous experience operating similar equipment, the operator

must be given sufficient opportunity to practice with the handler in a safe, open

area (not hazardous to people or property) to gain operating skills and the

proper “feel” for controls and operating clearances required for safe, efficient

operation.

GRADALL Material Handlers are equipped with a right-side rearview mirror.

This mirror is intended as an operator’s aid and does not replace the requirement

for line-of-sight. Certain job site and machine conditions may require use of a signal

person to help the operator when picking, placing or transporting a load. Never

operate the handler until you know pick-up point, line of travel and landing point

are clear. Always be aware that objects in mirror are closer than they appear.

Safety Precautions

Make sure all DANGER, WARNING, CAUTION and INSTRUCTIONAL DECALS

are in place and can be read. Clean or replace decals as required.

Ensure handler is on a firm, level surface before lifting or placing load. Have

surface leveled if necessary. Unit can tip over if load is raised with handler

on a soft or uneven surface.

Always look in the direction of travel. Reduce speed and be especially careful

when traveling in reverse and/or turning. Be aware of tail swing due to

rear-pivot steering.

If load or conditions obstruct view, use a signal person when lifting, carrying

or placing a load.

Loose clothing can get caught in moving machinery and can also cause accidental

actuation of controls. Dress properly for the job.

Be alert to any unusual response to controls. If unusual response is noticed,

position handler in a safe area, lower forks to ground, apply parking brake,

stop engine and remove key from ignition switch. Tag steering wheel to forbid

operation and notify maintenance personnel.

Keep hands, gloves, shoes, control knobs and pedals clean. Slippery controls

can cause accidents. Keep a firm grip on the steering wheel when traveling.

Load capacities are based on load center being within 24 inches

(610mm) from front vertical face of forks.

Never service the handler with the engine running.

Release trapped pressure before disconnecting, opening or removing any

hydraulic component.

This symbol indicates a hazard

which may result in injury or

damage to equipment or property

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.

This symbol indicates an extreme

hazard which will result in high

probability of death or serious

injury if proper precautions are not

taken.

WATCH FOR THESE SYMBOLS ;

THEY CALL YOUR ATTENTION

TO SAFETY NOTICES.

1.0

Operator must be seated with seat

belt fastened, forward reverse lever

in “Neutral” position, parking brake

applied and all hydraulic controls

in “Neutral” before starting engine.

DANGER

WARNING

CAUTION

WARNING

SAFETY HIGHLIGHTS

Form No. 20219

534D-9/534D-10 Owner/Operator Manual

1.1

Keep all windows and mirror(s) clean. Adjust mirror(s) as

required for maximum

visibility, before and during opera

tion.

Never permit diesel engine to run out of fuel. Doing so can cause severe

engine damage.

DO NOT burn or drill holes in forks. Modifying any part of machine or

attachment may affect machine capacity and/or stability.

Keep head, arms, hands, legs and all other body parts inside the operator’s

cab at all times.

DO NOT approach power lines, overhead or underground cables or other power

sources with any part of your material handler or load unless all local, state/

provincial and federal regulations have been met and the appropriate utility

company has been contacted to de-energize the lines.

Whenever leaving the cab, perform standard shut-down procedure:

Standard Shut-Down Procedure

Position the handler in a safe location, apply parking brake, lower forks to

ground, move all controls to

“Neutral”, allow engine to run at low idle for 3 to 5

minutes.

Stop engine and remove ignition key. Block wheels.

Pinch Points

Stay clear of pinch points and rotating parts on the material handler.

Getting caught 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”.

Contact The Gradall Company prior

to welding on machine.

WARNING

Rear Steering Axle Boom

Boom Holes Attachment Tilt

Carriage Forks Stabilizers

(D10 only)

2.0

INSIDE THE CAB

DECALS

Located on dashboard

P/N 9114-3120

Located on dashboard

P/N 9116-3184

Located on dashboard

P/N 9114-3182

9116-3184 REV. A

9134-3005 REV. B

LEVEL GRADALL HANDLER BEFORE LIFTING ABOVE 4 FT.

USE CAPACITY CHART FOR SPECIFIC ATTACHMENT ON MACHINE.

FOR OTHER ATTACHMENTS CONSULT A GRADALL DEALER

FOR LOAD RATINGS NOT LISTED.

USE LARGEST NUMBER VISIBLE FROM THE CAB TO

DETERMINE BOOM EXTENSION.

MATCH WITH BOOM ANGLE TO DETERMINE ALLOWABLE LOAD.

FIGURES SHOWN ARE STACKING CAPACITY TRUCK LEVEL.

RATED LIFTING CAPACITIES SHOWN ARE WITH MACHINE ON A FIRM,

LEVEL SURFACE WITH UNDAMAGED, PROPERLY INFLATED TIRES.

MACHINE SPECIFICATIONS AND STABILITY ARE BASED ON RATED LIFT

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 AND

DANGEROUS MACHINE CONDITIONS WILL RESULT.

DO NOT TIP THE MACHINE FORWARD TO DETERMINE ALLOWABLE LOAD.

CERTAIN CARRIAGE/FORK COMBINATIONS MAY CAUSE HANDLER TO TIP

WITHOUT LOAD WHEN EXTENDED INTO "NO OPERATION" ZONE AS NOTED

ON CAPACITY CHART.

CAPACITY LIMITS FOR THIS UNIT ARE BASED IN ACCORDANCE WITH

STANDARDS LISTED ON SERIAL NUMBER PLATE.

SAMPLE ONLY - USE CHART IN CAB

Located on dashboard

P/N 9134-3005

71°

60°

50°

40°

30°

20°

10°

0°

-7°

32'

48'

0'4'8'20' 12'16'

24'

28'

-4'

12'

16'

20'

24'

28'

32'

36'

40'

44'

36'

DEDUCT 300 LBS

FROM ALL CAPACITIES

WHEN MACHINE IS

EQUIPPED WITH WINCH

MODEL

534D9-45

USE WITH: 9045-5051 48" CARRIAGE

9045-5052 66" CARRIAGE

9055-5008 72" CARRIAGE

9135-5004 WINCH (3,000lb MAX CAPACITY)

9134-3064

9000 LB

8000 LB

00 LB

6000 LBS

5000 LBS

4000 LBS

3000 LBS

2000 LBS

1600 LBS

RATED CAPACITY @

2 FT. LOAD CENTER

SAMPLE ONLY - USE CHART IN CAB

Located on dashboard

P/N 9134-3064

9102-3006

Located on seat pedestal

P/N 9102-3006

MACHINE MUST BE

IN NEUTRAL AND

PARK BRAKE ON TO START

ACC

OFF

RUN

START

9114-3182

Form No. 20219

534D-9/534D-10 Owner/Operator Manual

2.1

INSIDE THE CAB

Located on forward/reverse lever

P/N 9116-3028

Located on lever knob

P/N 9108-3318

Located on dashboard

(Cummins Engines Only)

P/N 9114-3202

Located on lever knob

P/N 9108-3317

Located on dashboard

P/N 9108-3314

Located on joystick pedestal

P/N 9130-3047

Located on dashboard

P/N 9134-3016

Located on left cab wall

P/N 7733-3027

Located on dashboard

P/N 9116-3212

SAMPLE ONLY - USE CHART IN CAB

9134-3016

TURBOCHARGER DAMAGE CAN RESULT

FROM QUICK START-UP & SHUTDOWN.

FOR LONGER TURBOCHARGER LIFE

AND TO MINIMIZE TURBOCHARGER

DAMAGE, IDLE ENGINE AT LEAST

3-5 MINUTES AFTER START-UP

AND BEFORE SHUTDOWN.

9114-3202

STARTING AID INSTRUCTIONS

1. HOLD SWITCH ON FOR 3 SECONDS

TO FILL VALVE.

2. RELEASE SWITCH TO DISCHARGE

ETHER WHILE CRANKING ENGINE.

3. AS ENGINE STARTS, USE

ADDITIONAL ETHER AS REQUIRED

TO KEEP ENGINE RUNNING.

9130-3047

9116-3212

CERTAIN FORK/CARRIAGE COMBINATIONS MAY CAUSE

HANDLER TO TIP WHEN EXTENDED INTO "NO

OPERATION" ZONE AS NOTED ON CAPACITY CHART

WITH STABILIZERS UP CAUSING SERIOUS INJURY

OR DEATH. NEVER OPERATE MACHINE WITHOUT

CONSULTING PROPER CAPACITY CHART FOR THE

CARRIAGE/FORK COMBINATION BEING USED.

7733-3027

TRACTION LOCK SWITCH

9108-3314

DO NOT ENGAGE

WHEN WHEELS ARE

IN MOTION OR

ON IMPROVED

SURFACES. MACHINE

MUST BE IN 4

WHEEL DRIVE.

SWITCH LOCATED

ON FLOOR. SWITCH

HYDRAULICALLY

LOCKS FRONT AND

REAR WHEELS

TOGETHER FOR

INCREASED TRACTION.

2.2

Located on left side, front cab plate

P/N 9116-4097 (enclosed cab)

P/N 9116-4093 (open cab)

Located on right cab wall

(Cummins Engines Only)

P/N 9114-3292

Located on left side, front cab plate

P/N 9116-4094

INSIDE THE CAB

Located on right cab wall

P/N 9055-3028

Located on right cab wall

P/N 9134-3062 - 534D-9

P/N 9135-3210 - 534D-10

Located on left cab wall

P/N 9114-3283

ENGINE OIL

LEVEL

9114-3292

9114-3283

NO RIDERS PERMITTED ON HANDLER.

OPERATOR ONLY IN MACHINE

WHILE RUNNING.

RIDERS COULD FALL OFF MACHINE

CAUSING SERIOUS INJURY OR DEATH.

GRADALL MATER 06 / 9 / 10

MAX WEIGHT : 2150

MEETS SAE : J1040 MA

MEETS ISO : 3471 (94) / 3

MEETS ANSI : B56.6 - 8.16 / P

GRADALL : SERIAL :

Box 61 SD 57201

SAMPLE ONLY

000850

THE PROTECTION OFFERED BY THIS

ROPS WILL BE IMPAIRED IF IT HAS BEEN

SUBJECTED TO ANY MODIFICATION,

STRUCTURAL DAMAGE, OR HAS BEEN

INVOLVED IN AN OVERTURN INCIDENT.

THIS ROPS MUST BE REPLACED AFTER

A ROLL-OVER. SEAT BELTS MUST BE

WORN WHILE OPERATING VEHICLE.

8. ON INCLINES, TRAVEL WITH LOAD UP-GRADE.

9. DO NOT USE BOOM AS WALKWAY.

10. USE TWO HANDS WHEN CLIMBING ON MACHINE.

1. ONLY TRAINED AND AUTHORIZED PERSONNEL MAY

OPERATE THIS MACHINE.

2. BEFORE OPERATING, READ AND UNDERSTAND ALL CAPACITY

CHARTS, OPERATOR MANUALS AND SAFETY MANUALS. IF

MANUALS ARE NOT AVAILABLE, CONSULT AN AUTHORIZED

GRADALL DEALER. UNDERSTAND ALL CONTROLS IN CAB AND

CHECK FOR PROPER OPERATION. CLEAR LOOSE OBJECTS

OFF MACHINE AND SOUND HORN BEFORE STARTING ENGINE.

3. OPERATOR MUST BE SEATED WITH SEAT BELT FASTENED.

ASSURE FORWARD/REVERSE LEVER IS IN NEUTRAL,PARK

BRAKE APPLIED AND ALL HYDRAULIC CONTROLS ARE IN

NEUTRAL BEFORE IGNITION SWITCH IS TURNED ON.

4. DO NOT OPERATE MACHINE WITHOUT PROPER CAPACITY

CHART IN PLACE.

5. BEFORE MOVING, BE SURE OF A CLEAR PATH AND SOUND

HORN. WATCH FOR PEDESTRIANS AND OBSTRUCTIONS.

CHECK OVERHEAD AND SIDE CLEARANCES. ALWAYS LOOK

IN DIRECTION OF TRAVEL.

6. START, TURN, AND BRAKE SMOOTHLY. REDUCE TRAVEL

SPEEDS FOR TURNS, SLIPPERY, OR UNEVEN SURFACES.

AVOID RUNNING OVER LOOSE OBJECTS OR HOLES IN THE

ROADWAY SURFACE.

7. WHEN TRAVELING WITH LOAD, FULLY RETRACT BOOM AND

PLACE FORKS IN CARRY POSITION.

TILT CARRIAGE BACK SLIGHTLY TO CRADLE LOAD.

USE EXTREME CAUTION WHEN TURNING.

11. USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK

PLATFORM FOR LIFTING PERSONNEL. NO RIDERS ON MACHINE,

FORKS, LOAD, OR OTHER LIFTING ATTACHMENTS AT ANY

TIME. DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE

PROPER GRADALL MATERIAL HANDLER/PERSONNEL WORK

PLATFORM CAPACITY CHART DISPLAYED IN THE CAB. DO NOT

DRIVE MACHINE WITH PERSONNEL IN PLATFORM.

12. KEEP OTHERS AWAY FROM MACHINE WHILE OPERATING.

DO NOT STAND UNDER BOOM OR LOAD.

13. USE EXTREME CARE WHEN HANDLING LONG, HIGH, OR

WIDE LOADS. DO NOT HANDLE UNSTABLE OR LOOSELY

STACKED LOADS.

14. FORKS TO BE CENTERED UNDER LOAD AND SPACED APART

AS FAR AS POSSIBLE.

15. BEFORE ADJUSTING OR SERVICING, PLACE

FORWARD/REVERSE LEVER IN NEUTRAL, REST BOOM ON

GROUND OR SUPPORT, SET PARKING BRAKE, SHUT OFF

ENGINE AND CHOCK WHEELS.

16. BEFORE LEAVING MACHINE UNATTENDED, PLACE

FORWARD/REVERSE LEVER IN NEUTRAL, LOWER BOOM,

SET PARKING BRAKE,AND SHUT-OFF ENGINE. CHOCK

WHEELS IF MACHINE MUST PARK ON AN INCLINE.

17. LEVEL MACHINE BEFORE LIFTING ANY LOAD ABOVE 4

FEET. (IF EQUIPPED WITH FRAME LEVELING).

18. OPERATOR PROTECTION (SUCH AS HARD HATS, SAFETY

GLASSES, AND/OR HEARING PROTECTION) SHOULD BE

WORN WHEN JOB CONDITIONS WARRANT. ALWAYS USE

SEAT BELT.

19. IMPROPER USE OF MACHINE COULD RESULT IN MACHINE

TIPPING OVER. IF MACHINE STARTS TO TIP OVER, DO

NOT LEAVE OPERATORS SEAT. LEAN AWAY FROM TIP &

BRACE YOURSELF.

20. KEEP MIRROR(S) CLEAN AND PROPERLY ADJUSTED.

OBJECTS IN MIRROR ARE CLOSER THAN THEY APPEAR.

9055-3028 REV. A

FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF

SERIOUS INJURY, READ AND OBSERVE THE FOLLOWING:

TRUSS BOOM

P/N 9045-5011

24,180

TRUSS BOOM W/WINCH

P/N 9045-5012

24,420

26,190

26,450

6' MAST W/48" CARR

P/N 9045-5035

25,380

6' MAST W/66" CARR

P/N 9045-5037

25,460

72" 100° SWING CARR

P/N 9045-5044

25,160

48" SLOPE PILER

P/N 9108-5058

24,630

66" SLOPE PILER

P/N 9130-5016

24,750

6' SW. MAST W/48" FORKS

P/N 9045-5047

6' SW. MAST W/60" FORKS

P/N 9045-5054

1.6

--- ---

24 24

3.7

8.7

-.7

-1.6

WORK PLATFORM

P/N 9055-5024

2.7

24,520

24,040

-.9

4.5

24,220

2.3

24,540

24 24

AS RELEASED FROM FACTORY THIS TRUCK MEETS THE DESIGN SPECIFICATIONS

ATTACHMENT

DCBA

24,420

9134-3062 (REV. D)

(WITHOUT

ATTACHMENTS)

36 40

24 24

-.9

23,570 LBS

36 24 24

-.9

24 24

45 --- ---

24,320

--- ---

III

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.

ESTABLISHED IN AMERICAN NATIONAL STANDARDS FOR POWERED INDUSTRIAL

TRUCKS PART ASME B56.6b-1998.

CAPACITY WITH STANDARD

48", 66", & 72" CARRIAGE

CAP#

1000

TRUCK &

ATTACHMENT

WEIGHT

SHIPPED

WITH

CAP#

X1000

*WEIGHTS ARE BASED ON USING 1 3/4 X 6 X 48" FORKS (APPROX. 356# PER PAIR)

**BUCKET DIMENSIONS (A & D) REFER TO BUCKET LIP HEIGHT.

***TRUSS BOOM, WINCH & QUICK HOOK DIMENSIONS (A & D) REFER TO HOOK CENTER.

****WEIGHT IS BASED ON SP'L SWING MAST FORKS (48": APPROX. 220# PER PAIR)

(60": APPROX. 490# PER PAIR)

*****PLATFORM DIMENSIONS (A & D) REFER TO CENTER OF FLOOR.

48" CARRIAGE

P/N 9045-5051

66" CARRIAGE

P/N 9045-5052

72" CARRIAGE

P/N 9055-5008

3/4 YD BUCKET

P/N 9045-5049

1 1/4 YD BUCKET

P/N 9055-5020

534D9-45

GRADALL IS A REGISTERED TRADEMARK

FOR HYDRAULIC EQUIPMENT

BUILT BY THE JLG COMPANY

1 JLG DRIVE, McCONNELLSBURG, PA.

U.S.A.

****

***

****

FT IN IN

IN IN

FT FT

IN IN

SAMPLE ONLY - USE CHART IN CAB

Form No. 20219

534D-9/534D-10 Owner/Operator Manual

2.3

Located on hydraulic reservoir

P/N 9116-3130

Located on hydraulic filter bracket

P/N 9114-3162

OUTSIDE THE CAB

Located on valve access cover in cab

Located on hydraulic reservoir

P/N 9108-3492

Located on hydraulic reservoir

P/N 9114-3288

Located on sheet metal cover of

hydraulic reservoir and fuel tank

P/N 9114-3281

Located on engine

(Cummins Engines Only)

P/N 9116-3256

Located on right and left rear frame,

hydraulic reservoir & boom head

P/N 9114-3282

WHEN REPLACING COOLANT OR IN

CASE OF COOLANT LOSS PURGE AIR

BY OPENING DE-AERATION PETCOCK

WHILE ENGINE IS RUNNING.

9114-3281

STAY CLEAR OF MOVING PARTS

WHILE ENGINE IS RUNNING.

MOVING PARTS CAN CAUSE

SERIOUS INJURY.

ADD

CHECK OIL LEVEL WITH

HANDLER LEVEL AND ALL

CYLINDERS RETRACTED.

1 GALLON BETWEEN

ADD AND FULL MARKS

FULL

HYDRAULIC

OIL LEVEL

9116-3130

9114-3282

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.

BEING IN PINCH POINT AREA COULD

CAUSE SERIOUS INJURY OR DEATH.

9114-3162

For Mobil Product Information, Call 1-800-662-4525.

HYDRAULIC SYSTEM

FILL WITH TRACTOR HYDRAULIC FLUID

or equivalent.

9114-3288

Genuine Parts

Located on boom

P/N 8060-3037

2.4

OUTSIDE THE CAB

Located on mud guard

P/N 8060-3022

Located on engine compartment

P/N 9114-3280

Located on fuel tank

P/N 9114-3286

Located on engine cover

P/N 8060-3026

Located beside battery

P/N 9114-3284

Located beside battery

P/N 9114-3285

9114-3280

EXHAUST SYSTEMS CAN BE HOT.

KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.

HOT EXHAUST COMPONENTS CAN CAUSE

SEVERE BURNS.

8060-3026

COOLING SYSTEM

IS PRESSURIZED.

REMOVE CAP SLOWLY.

HOT FLUID CAN

CAUSE BURNS.

9114-3285

WHEN JUMP STARTING MATERIAL HANDLER

* NEVER ALLOW VEHICLES TO TOUCH

* CONNECT THE POSITIVE (+) JUMPER CABLE TO

POSITIVE (+) POST OF DISCHARGED BATTERY

* CONNECT OPPOSITE END OF POSITIVE (+) JUMPER

CABLE TO POSITIVE (+) POST OF BOOSTER BATTERY

* CONNECT THE NEGATIVE (-) JUMPER CABLE TO

NEGATIVE (-) POST ON BOOSTER BATTERY

* CONNECT OPPOSITE END OF NEGATIVE (-) JUMPER

CABLE TO GROUND POINT ON MACHINE AWAY FROM

DISCHARGED BATTERY

* FOLLOW STANDARD STARTING PROCEDURES

* REMOVE CABLES IN REVERSE ORDER AFTER MACHINE

HAS STARTED

JUMP STARTING INSTRUCTIONS

9114-3284

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

8060-3037-A

PINCH POINT

KEEP OUT

REACHING INTO BOOM

HOLES AND OTHER PINCH

POINTS CAN CAUSE

SERIOUS INJURY

OR DEATH.

8060-3022

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.

9114-3286

DIESEL FUEL IS FLAMMABLE

EXTINGUISH ALL OPEN FLAME AND

SMOKING MATERIALS WHEN REFUELING

INJURY OR DEATH COULD RESULT

FROM FIRE.

Form No. 20219

534D-9/534D-10 Owner/Operator Manual

2.5

Located on left side of boom

P/N 9100-3031

OUTSIDE THE CAB

Located on mudguard

P/N 9134-3073

Located on boom head

P/N 9055-3026

Located on attachment

P/N 9015-3001

Located on mudguard

P/N 9055-3027

Located on Personnel Work Platform

P/N 9055-3032

Located on Personnel Work Platform

P/N 9055-3031

Located on Personnel Work Platform

P/N 9055-3033

Located on boom head

P/N 9114-3290

9055-3027 REV. A

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.

406 MILL AVE. S.W. NEW PHILADELPHIA, OHIO MADE IN U. S. A.

THE CAPACITY OF FORKLIFT, ATTACHMENT AND FORK

COMBINATION MAY BE LESS THAN THE CAPACITY SHOWN

ON ATTACHMENT - CONSULT FORKLIFT NAMEPLATE

AND ALSO INSURE FORKS ARE OF PROPER SIZE.

9015-3001

ATTACHMENT

SERIAL NUMBER

WEIGHT

CAPACITY

HYD. PRESSURE

ATTACH LANYARD HERE

9055-3032

9055-3026 REV. A

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED

PERSONNEL WORK PLATFORM.

ALL PERSONNEL IN PLATFORM MUST WEAR A FULL BODY HARNESS WITH

LANYARD ATTACHED TO A DESIGNATED ANCHORAGE POINT.

READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL

BEFORE OCCUPYING PERSONNEL WORK PLATFORM.

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

9055-3031 REV. A

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.

406 MILL AVE. S.W. NEW PHILADELPHIA, OHIO MADE IN U. S. A.

DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE

PROPER GRADALL MATERIAL HANDLER/PERSONNEL WORK

PLATFORM CAPACITY CHART DISPLAYED IN CAB.

9055-3033

ATTACHMENT

SERIAL NUMBER

WEIGHT

CAPACITY

HYD. PRESSURE

-------------------------------------------------------

REAR AXLE WHEEL END LUBE(4 PT.)

TIRES: 14.00x24(12 PLY) 65 PSI

FRONT AXLE

(5 GAL)

MOBIL 424

BATTERY & TERMINALS

DIESEL ENGINE

AIR CLEANER ELEMENTS

FUEL FILTERS

OIL FILTER

OIL (12 QT.)

DIESEL FUEL (40 GAL.)

HYD.TANK BREATHER/FILTER CAP

QUICK SWITCH (1) FITTING

TIRES: RADIAL 70 PSI

FRONT AXLE PIVOT (2) FITTINGS

ALL BEARINGS PADS

HEAD PIN (2) FITTINGS

ANNUALLY

1500 HRS

DAILY

10 HRS

WEEKLY

50 HRS

EVERY

5WKS OR

250 HRS

3 MO.

500 HRS

SERVICE INTERVALS

TYPE OR

EQUIVALENT

RADIATOR

3 GAL. WATER

3 GAL ANTI-FREEZE

WHEEL NUT TORQUE-350/400 FT-LBS

9134-3073 REV -

TIRES: 13.00x24(12 PLY) 65 PSI

CHECK

INSPECT

CHECK

REAR AXLE (12) FITTINGS

BOOM PIVOT (2) FITTINGS

TORQUE

CHECK

CHANGE

CYLINDER FITTINGS EACH END

RETRACT & EXTEND CABLE

SEE OPERATOR & MAINTENANCE MANUAL

CHANGE

FILL

OIL (47 GAL.)

CHECK

GREASE

CHECK

6 MO.

1000 HRS

CHANGE

FRONT BOTTOM BEARING PADS

GREASE

CHECK

GREASE

BOOM SHEAVES (3) FITTINGS

HYDRAULIC SYSTEM

FILTERS

ETHYLENE GLYCOL

ANTI-FREEZE

SAE 15W-40-CD ***

DIESEL FUEL #2

GRADALL HANDLER

SERVICE INSTRUCTIONS

FOR: 534D-9, 534D-10

CONSULT DEALER FOR RECOMMENDATIONS AT EXTREME TEMPERATURES.

THIS CHART MUST BE USED IN CONJUNCTION WITH SERVICE MANUAL AND RECOMMENDED PROCEDURE.

CHECK INDICATOR ON HYDRAULIC FILTER. CHANGE FILTER IF NEEDLE IS IN YELLOW

AT FULL THROTTLE & AT OPERATING TEMPERATURE.

CHECK AIR CLEANER RESTRICTION INDICATOR. CLEAN OR CHANGE PRIMARY FILTER IF NECESSARY.

SAFETY ELEMENT TO BE CHANGED EVERY 3RD CHANGE OF PRIMARY FILTER ELEMENT.

IT IS RECOMMENDED THAT FILTER ELEMENTS AND FRONT AXLE LUBRICANT BE CHANGED AFTER

FIRST 50 HRS ON NEW OR REBUILT UNITS.

DAILY SERVICE MAY BE REQUIRED FOR OPTIMUM LIFE DEPENDING UPON APPLICATION SEVERITY.

MOBIL 424

CHECK

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MYSTIK TETRIMOLY

SAMPLE ONLY - USE CHART IN CAB

****

OPERATOR’S CAB

The standard cab permits vision from all sides and includes an overhead guard

to provide protection from falling objects.

A fully-enclosed cab with windows and a lockable door is available as an option.

The top half of the cab door must be secured in the fully-opened or closed

position. The bottom half of the cab door can be secured in the closed position

only. Be sure the door is fully secured when operating the handler.

The operator’s seat is equipped with a seat belt and includes fore and aft

adjustment to compensate for variations in operator size. The adjustment

release/lock is located beneath

ront edge of seat. Wear seat belt when

operating machine.

An optional windshield wiper/washer is available for use with enclosed cabs. A

control switch is located on the instrument panel.

A variable-speed defroster fan is available for use with enclosed cabs. An “On/

Off” control switch and speed control are located on the base of the fan.

A heater fan is available for use with units equipped with a heater. An “On/Off”

switch is located on the dashboard. Hot water to the heater can be controlled

by a valve at the engine.

The operator’s cab is an S.A.E. “FOPS/ROPS” structure. Do not make

any modification to this structure. If damaged, the cab cannot be

repaired. It must be replaced.

CONTROL AND INSTRUMENT IDENTIFICATION

OPERATOR’S CAB

3.0

Never operate the handler unless

the overhead guard is in place and

in good condition.

NOTE!

Relevant S.A.E. Recommended

Practices:

S.A.E. J1040 for ROPS

S.A.E. J231 for FOPS

WARNING

Any modification to this machine

must be approved by GRADALL to

assure compliance with FOPS/

ROPS certification for the cab/

machine configuration.

Figure 3-1

Form No. 20219

534D-9/534D-10 Owner/Operator Manual

Accelerator Pedal: Depress pedal to increase speed and release pedal to

decrease speed.

Alternator Indicator Light: Glows (red) to indicate alternator is not charging.

Attachment Tilt Lever: This lever controls tilt of the fork carriage. Speed is

proportional to lever actuation and engine RPM. Push lever forward to tilt down;

pull lever back to tilt up.

Attachment Tilt Switch (optional): Depress front of switch

to tilt down; depress

rear of switch to tilt up.

Auxiliary Control Lever (optional): This lever is used to control optional

hydraulic attachments. Follow decal instructions for lever/handler movements.

Auxiliary Light Switch (optional):

This switch turns auxiliar

y lights on and

off.

Boom Control Joystick:

This joystick controls boom elevation

and extension.

Pull joystick back to raise boom;

push joystick

forward to lower boom. Move

joystick to right to extend boom; move to left to retract boom. Speed of boom

movement is proportional to joystick actuation and engine RPM.

Check Engine Light (Deere Engines Only): Glows (red) for 30 seconds before

engine shuts down when a “Shutdown” fault is detected.

Engine Coolant Temperature Gauge: This gauge displays engine coolant

temperature.

Engine Oil Pressure Gauge: This gauge displays engine oil pressure.

Forward/Reverse Lever: This lever engages forward or reverse travel. Lift &

push lever fully forward for forward travel; Lift & pull lever fully backward for

reverse travel. Move lever to centered position for “Neutral”.

Fuel Gauge: This gauge displays level of fuel in fuel tank.

Heater Fan Switch (optional): This switch turns heater fan on and off.

Horn Button: Depress button to sound horn.

Hourmeter: This meter indicates total time of engine operation in hours and

tenths of hours.

Ignition Switch: This switch is actuated by a key. In “ACC” or “RUN” position,

voltage is available for all electrical functions. Full clockwise rotation to “START”

engages starter motor.

Counter-clockwise rotation to “OFF” stops engine and

moves voltage from all electrical functions.

Level Indicator: This bubble level indicator enables the operator to determine

the left to right level condition of the handler.

Lights Switch (optional): This switch controls optional lighting which may

be provided with the handler.

Machine Level Lever: This lever controls the relationship of the handler frame

to the front axle. Push the lever forward to tilt frame to left, pull lever back to

tilt frame to right.

Parking Brake Switch: This switch controls the application and release of the

parking brake.

3.1

A brief description of controls and

instruments is provided here as a

convenience for the operator.

These descriptions DO NOT provide

complete operation instructions.

Read & understand this Manual,

and the GRADALL Material Handler

Safety Manual.

WARNING

+ 37 hidden pages