Gradall G6-42P Operation Manual

G6-42P MATERIAL HANDLER

OWNER/OPERATOR MANUAL

COVERING OPERATION & PERIODIC MAINTENANCE

material handler

Read and understand this Manual and the Gradall Material

Handler Safety Manual before starting, operating or

performing maintenance procedures on this machine.

IMPORTANT!

KEEP OPERATOR AND SAFETY MANUALS IN CAB

A Company

Form No. #20027

COVERS MATERIAL HANDLER MODEL G6-42P

STARTING SERIAL NUMBERS

0189001 THRU 0189345,

& 0160000230 THRU 0160004017

Part No. 9140-4003

Revised 11-25-08

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IMPORTANT SAFETY NOTICE

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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 G6-42P Material Handler. Detailed maintenance information is available in the appropriate Service Manual.

Any procedure not specifically recommended by GRADALL must be thoroughly evaluated from the standpoint of safety before it is placed in practice. If you are not sure, contact your GRADALL Material Handler Distributor before operating.

Use only GRADALL authorized parts. The use of counterfeit parts may cause premature failure which could lead to injuries and/or machine damage.

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Do not modify this machine without written

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permission from GRADALL. Use only genuine

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GRADALL replacement parts.

OTHER NOTICES

GRADALL retains all proprietary rights to the information contained in this Manual.

GRADALL reserves the right to change specifications without notice.

Gradall is a registered trademark for Hydraulic Excavators, Hydraulic Material Handlers and Attachments manufactured by The Gradall Company.

REVISIONS

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

Page Date Revision

11.0 9/24/01 Revised section on checking and adjusting boom.

16.0 7/22/02 Added an additional lubrication notice.

Cover 5/23/03 Revised All

Intro Revised Operator Qualification section.

TOC Added page 20.2 to Table Of Contents.

2.0 Replaced 9140-3525 Decal with 9150-3102 Decal.

2.1 Added 9134-3016 & 9141-3061 Decals & P/N to Angus-Palm Decal.

2.4 Removed 9134-3016 Decal; added 9114-3290 Decal; revised P/N on 9055-3027.

3.0 Revised Operator’s Cab section.

6.0 Revised Optional Cold-Weather Starting Aid section.

9.0 Revised Steering System section.

10.0 Revised General section.

13.1 Removed Figure 13-4, revised Load Center section.

14.7 Revised Figure 14-8.

17.0 Revised Front Axle and Rear Hub Capacities.

18.0 Revised Rear Hub Torque Values; added Flexplate Mounting Bolts Torque Values.

20.1 Added Meritor Axle to title of page.

20.2 Added page for Carraro Axle.

Cover 11/08 Added ending Serial Number

Form No. 20027 • G6-42P Owner/Operator Manual

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

TABLE OF CONTENTS INTRODUCTION

General Operator Qualifications Orientation Related Manuals & Decals

Serial Number Location NOMENCLATURE

SAFETY ................................................................................. 1.0 thru 1.2

DECALS ................................................................................. 2.0 thru 2.4

Decals Inside Cab

Decals Outside Cab

OPERATORS CAB ..................................................................... 3.0 thru 3.2

Cab

Control & Instrument Identification

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

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

ENGINE OPERATION ................................................................ 6.0 thru 6.1

Starting the Engine

Cold-Weather Starting Aids

Battery-Boosted Starting

Normal Engine Operation

Stopping the Engine

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

General

Inching Travel

Service Brakes

Parking Brakes

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

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

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

BOOM .................................................................................... 11.0

LEVELING THE HANDLER .......................................................... 12.0 thru 12.1

OPERATING PROCEDURE & TECHNIQUES ................................... 13.0 thru 13.1

Hydraulic Controls

Rated Capacity Chart

ATTACHMENTS ........................................................................ 14.0 thru 14.7

Approved Attachments

Non-Approved Attachments

Carriage/Fork Capacities

Other Attachment Capacities

Attachment Installation

Attachment Operation

LOADING & SECURING FOR TRANSPORT .................................... 15.0

LUBRICATION & MAINTENANCE................................................. 16.0 thru 16.1

RECOMMENDED LUBRICANTS & CAPACITIES .............................. 17.0

TORQUE CHART ...................................................................... 18.0

OBTAINING HYDRAULIC OIL SAMPLE FOR ANALYSIS .................... 19.0

MOVING HANDLER IN EMERGENCY ............................................ 20.0 thru 20.2

Moving Short Distances

Moving Longer Distances

To Activate Tow Bypass

To Release Parking Brake

To Restore Parking Brake INSPECTION AND MAINTENANCE LOG

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

INTRODUCTION

** unknown ** ** unknown **

General

This Manual provides important information regarding safe operating procedures and maintenance requirements for GRADALL G6-42P Material Handlers.

If you have any questions regarding the material handler, contact your GRADALL Material Handler Distributor.

NOTE!

“Material handler” and handler are used interchangeably throughout this Manual.

Operator Qualifications

Operators of the material handler must be in good physical and mental condition, have normal reflexes and reaction time, good vision and depth perception and normal hearing. He must not be using medication which could impair abilities nor be under the influence of alcohol or any other intoxicant during the work shift.

The operator should possess a valid, applicable driver’s license and must have completed a training course meeting the OSHA Powered Industrial Truck Operator Training Requirements (CFR 1910.178) for this type of material handling equipment.

In addition, the operator must read/view, understand and comply with instructions contained in the following material furnished with the material handler:

• This Owner/Operator Manual

• GRADALL Material Handler Safety Manual

• All instructional decals and plates

• Any optional equipment instructions furnished

The operator must also read, understand and comply with all applicable Employer, Industry and Governmental rules, standards and 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)

NOTE!

Though no offense or discrimination is intended, only the masculine pronouns will be used throughout the remainder of this Manual.

FRONT

RIGHT

LEFT

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 the G6-42P Material Handler. This unit is equipped with a three-section boom and four-wheel drive. Optional equipment available for use with this unit is described in appropriate sections of the Manual. Be certain to refer to proper information for your unit and the operational equipment furnished on your machine.

Serial Number Location

Specify Model Number and Serial Number when ordering parts and when discussing specific applications and procedures with your Distributor. The model/ serial number plate is located inside the operator’s cab, right wall.

(See Figure I-2)

Nomenclature

The illustrations on the next page include nomenclature applied to major components of the material handler.

Form No. 20027 • G6-42P Owner/Operator Manual

REAR

Figure I-1

GRADALL IS A REGISTERED TRADEMARK FOR HYDRAULIC EQUIPMENT BUILT BY THE

MATERIAL HANDLER

406 MILL AVE S.W.,NEW PHILADELPHIA, OHIO 44663

MODEL MACHINE SERIAL NO ENGINE SERIAL NO

WEIGHT

SAMPLE ONLY - USE CHART IN CAB

AS RELEASED FROM FACTORY THIS TRUCK MEETS THE DESIGN SPECIFICATIONS ESTABLISHED IN AMERICAN NATIONAL STANDARDS FOR POWERED INDUSTRIAL TRUCKS PART III ASME B56.6b-1998.

CAPACITY WITH STANDARD

48" & 72" CARRIAGE.

CAP# X1000

SHIPPED

ATTACHMENT

WITH

48" CARRIAGE P/N 9140-5043 *

72" CARRIAGE P/N 9140-5045 *

48" SLOPE PILER P/N 9140-5101 *

72" SLOPE PILER P/N 9140-5079 *

*WEIGHTS ARE BASED ON USING 2 X 4 X 48" FORKS (APPROX. 268# PER PAIR) **BUCKET DIMENSIONS (A & D) REFER TO BUCKET LIP HEIGHT. ***TRUSS BOOM, WINCH & QUICK HOOK DIMENSIONS (A & D) REFER TO HOOK CENTER.

FORKS RATED LESS THAN THE ATTACHMENT CAPACITY SHOWN ABOVE DECREASE CAPACITY OF ATTACHMENT TO THAT OF FORKS. FORKS RATED MORE THAN ATTACHMENT CAPACITY DO NOT INCREASE ATTACHMENT CAPACITY.

GRADALL CO. MANUFACTURED IN THE U.S.A.

G6-42P

(WITHOUT ATTACHMENTS)

6.6

36'

24"

19,640 LBS

1.3

4'6"

24"

26'10"

TRUCK &

CAP#

ATTACHMENT

1000

WEIGHT

6.6

20,460

6.6

20,570

6.6

20,808

6.6

20,856

36' 24" 24" 0"

36' 24"

24"

37' 24" 24"

24"24"37'

9141-3009 (-)

** unknown ** ** unknown ** 3 NO

DCBA

11"

Figure I-2

NOMENCLATURE

SWAY CYLINDER

TIE-DOWN LUGS

FRONT DRIVE

AXLE

ENGINE & VALVE

COMPARTMENT

MIRROR

BATTERY

ENGINE

AIR

CLEANER

OPERATORS

CAB

HYDRAULIC

FILTERS

CONTROL

VALVES

HYDROSTATIC

TRANSMISSION

IMPLEMENT

STEERING

AXLE

PUMP

STEERING CYLINDER

TIE DOWN

LUGS

BOOM

SECTION 3

BOOM

HEAD

SECTION 2

QUICKSWITCH

BOOM

SECTION 1

HYDRAULIC RESERVOIR

ATTACHMENT

TILT CYLINDER

LUG NUTS

OPERATORS

CAB

HYDRAULIC RESERVOIR

BREATHER

LIFT

CYLINDER

FUEL TANK

PLANETARY

HUB

COUNTER-

WEIGHT

1.0

SAFETY

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 meeting the OSHA Powered Industrial Truck Operator Training Requirements (CFR 1910.178) for this type of material handling equipment.

Regardless of previous experience operating similar equipment, the 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.

WATCH FOR THESE SYMBOLS ; THEY CALL YOUR ATTENTION TO SAFETY NOTICES.

DANGER

This symbol indicates an extreme hazard which will result in high probability of death or serious injury if proper precautions are not taken.

WARNING

This symbol indicates a hazard which could result in death or serious injury if proper precautions are not taken.

CAUTION

This symbol indicates a hazard which may result in injury or damage to equipment or property if proper precautions are not taken.

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 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.

WARNING

Operator must be seated with seat belt fastened, forward reverse lever in “Neutral” position, parking brake applied and all hydraulic controls in “Neutral” before starting engine.

Form No. 20027 • G6-42P Owner/Operator Manual

1.1

Keep all windows and mirror(s) clean. Adjust mirror(s) as visibility, before and during opera

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

DO NOT burn or drill holes in forks. Modifying any part of machine or attachment affects it’s capacity and/or stability of machine.

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

DO NOT approach power lines, overhead or underground cables or other power sources with any part of your material handler or load unless all local, state/ provincial and federal regulations have been met and the appropriate utility company’s hotline has been contacted to de-energize the lines.

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

tion.

Standard Shut-Down Procedure

Position the handler in a safe location, apply parking brake, lower forks to ground, make sure all controls are in to 5 minutes.

Stop engine and remove ignition key. Block wheels.

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

required for maximum

WARNING

Contact The Gradall Company prior to welding on machine.

1.2

Pinch Points

Stay clear of pinch points and rotating parts on the material handler. Getting caught in a pinch point or a moving part can cause serious injury or death. Before performing any maintenance on machine, follow the “STANDARD SHUT-DOWN PROCEDURE” on page 1.1.

Rear Steering Axle

Boom Holes Attachment Tilt Cylinder

Boom

Form No. 20027 • G6-42P Owner/Operator Manual

Carriage Forks

2.0

DECALS

INSIDE THE CAB

NOTES

USE CAPACITY CHART FOR SPECIFIC ATTACHMENT ON MACHINE.

GENERAL

SAMPLE ONLY - USE CHART IN CAB

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.

LEVEL GRADALL HANDLER BEFORE LIFTING ABOVE 4 FT.

TRACTION LOCK

LOCKS FRONT & REAR AXLES

HYDRAULICALLY FOR INCREASED

TRACTION. DO NOT USE ON

IMPROVED SURFACES.

MACHINE MUST BE IN WORK

MODE

9140-3529

Located above traction lock pedal

P/N 9140-3529

DEDUCT 350 LBS FROM ALL CAPACITIES WHEN MACHINE IS EQUIPPED WITH WINCH

48'

44'

40'

36'

32'

48" & 72"

SLOPE PILER

28'

24'

20'

16'

12'

10°

0°

-4'

-8'

9140-3618

BACK

FRONT

Located on dashboard

P/N 9140-3618

MODEL G6-42P

RATED CAPACITY @ 2 FT. LOAD CENTER

SAMPLE ONLY - USE CHART IN CAB

50°

40°

30°

20°

2000 LBS

900 LBS

-9°

USE WITH: 9140-5101 48" 9140-5079 72" SLOPE PILER CARRIAGE

BACK

70°

60°

6600 LBS

4000 LBS

5000 LBS

3000 LBS

12'16'20'24'28'32'

4'8'

9141-3011 (-)

MODEL G6-42P

RATED CAPACITY @ 2 FT. LOAD CENTER

70°

6600 LBS

0' 4' 8'

USE WITH: 9140-5043 48" CARRIAGE 9140-5045 72" CARRIAGE 9140-5024 WINCH (4,000lb MAX. CAPACITY)

Located on dashboard

P/N 9141-3011

9140-3618

DEDUCT 350 LBS

FROM ALL CAPACITIES

WHEN MACHINE IS

EQUIPPED WITH WINCH

60°

50°

40°

30°

4000 LBS

5000 LBS

6000 LBS

12' 16' 20' 24' 28' 32'

3000 LBS

20°

2000 LBS

1300 LBS

FRONT

10°

0°

-9°

9141-3011 (-)

48'

44'

40'

36'

32'

28'

24'

20'

16'

12'

-4'

-8'

48" & 72"

CARRAIGES

9150-3102 REV. -

Located on right cab wall

P/N 9150-3102

NEVER OPERATE MACHINE WITHOUT

CONSULTING PROPER CAPACITY CHART FOR THE

CARRIAGE/FORK COMBINATION BEING USED.

9132-3030

Located on right cab wall

P/N 9132-3030

FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF

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.

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.

10. 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.

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.

Located on right cab wall

P/N 9055-3028

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

2.1

** unknown ** ** unknown **

INSIDE THE CAB

MATERIAL HANDLER

406 MILL AVE S.W.,NEW PHILADELPHIA, OHIO 44663

MODEL MACHINE SERIAL NO ENGINE SERIAL NO

WEIGHT

SAMPLE ONLY - USE CHART IN CAB

SHIPPED

(WITHOUT ATTACHMENTS)

AS RELEASED FROM FACTORY THIS TRUCK MEETS THE DESIGN SPECIFICATIONS ESTABLISHED IN AMERICAN NATIONAL STANDARDS FOR POWERED INDUSTRIAL TRUCKS PART III ASME B56.6b-1998.

CAPACITY WITH STANDARD

48" & 72" CARRIAGE.

CAP#

6.6

X1000

36'

24"

ATTACHMENT

WITH

48" CARRIAGE P/N 9140-5043 *

72" CARRIAGE P/N 9140-5045 *

48" SLOPE PILER P/N 9140-5101 *

72" SLOPE PILER P/N 9140-5079 *

1.3

4'6"

24"

26'10"

CAP# 1000

TRUCK & ATTACHMENT WEIGHT

6.6

GRADALL IS A REGISTERED TRADEMARK FOR HYDRAULIC EQUIPMENT BUILT BY THE GRADALL CO. MANUFACTURED IN THE U.S.A.

G6-42P

19,640 LBS

36' 24" 24" 0"

20,460

36' 24"

20,570

37' 24" 24"

20,808

20,856

SAMPLE ONLY -

USE CHART IN CAB

Box 61 SD 57201

GRADALL MATER 06 / 9 / 10 MAX WEIGHT : 2150 MEETS SAE : J1040 MA MEETS ISO : 3471 (94) / 3

** unknown ** ** unknown ** 3 NO

DCBA

24"

11"

24"24"37'

11"

MEETS ANSI : B56.6 - 8.16 / P GRADALL : 9114-3261 SERIAL : 8

Located on back wall, behind

operator’s seat

P/N 9140-4289 (enclosed cab)

P/N 9140-4111 (open cab)

FORKS RATED LESS THAN THE ATTACHMENT CAPACITY SHOWN ABOVE DECREASE CAPACITY OF ATTACHMENT TO THAT OF FORKS. FORKS RATED MORE THAN ATTACHMENT CAPACITY DO NOT INCREASE ATTACHMENT CAPACITY.

9141-3009 (-)

Located on right cab wall

P/N 9141-3009

GRADALL HANDLER SERVICE INSTRUCTIONS FOR: G6-42P

DIESEL ENGINE AIR CLEANER ELEMENT--------------**--------------------------------------------FUEL FILTERS-------------------------------------OIL FILTER--------------------------------OIL (14.5 QT.) (13.6 LTR.)----DIESEL FUEL (38 GAL.) (143.8 LTR.) HYDRAULIC SYSTEM

SAMPLE ONLY - USE CHART IN CAB

OIL (43 GAL.)------------------ -------------FILTERS--------------------------*----------------------------HYD.TANK BREATHER/FILTER CAP FRONT AXLE LUBE

CENTER SECTION (15.75 QT.)(14.9 LTR.) EACH WHEEL HUB (1.4 QT.)(1.3 LTR.)

REAR AXLE WHEEL END LUBE (4 PT.) (1.9 LTR.) WHEEL NUT TORQUE-300/350 FT-LBS RADIATOR (1.9 GAL.) (7.2 LTR.) WATER

(1.9 GAL.) (7.2 LTR.) ANTI-FREEZE (.5 QT.)(.47 LTR.) OF SUPPLIMENTAL COOLANT ADDITIVE (SCA)

TIRES: (12 PLY) 65 PSI ------------------------------ --------------------------

TIRES: RADIAL 70 PSI CYLINDER FITTINGS EACH END -----****REAR AXLE (12) FITTINGS --------****-

FRONT AXLE PIVOT (2) FITTINGS

ALL BEARINGS PADS FRONT BOTTOM BEARING PADS ----------BOOM PIVOT (2) FITTINGS---------****-

HEAD PIN (2) FITTINGS-----------****-

QUICK SWITCH (1) FITTING------------RETRACT & EXTEND CHAIN --------------------SEE OPERATOR & MAINTENANCE MANUAL

RETRACT & EXTEND CHAIN SHEAVES----------------

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

* CHECK INDICATOR ON HYDRAULIC FILTER. CHANGE FILTER IF NEEDLE IS IN RED

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

*** CONSULT DEALER FOR RECOMMENDATIONS AT EXTREME TEMPERATURES.

**** DAILY SERVICE MAY BE REQUIRED FOR OPTIMUM LIFE DEPENDING UPON APPLICATION SEVERITY. *****IF COOLANT IS ADDED TO RADIATOR ADD 3% SCA BY VOLUME.

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

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

AT FULL THROTTLE AND AT OPERATING TEMPERATURE.

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

IT IS RECOMMENDED THAT FILTER ELEMENTS, FRONT AXLE LUBRICANT, AND ENGINE OIL BE CHANGED AFTER FIRST 100 HRS ON NEW OR REBUILT UNITS.

SERVICE INTERVALS

DAILY

WEEKLY

EVERY

10 HRS

CHECK

FILL

CHECK

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

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

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

--------

3 MO.

5WKS OR

50 HRS

250 HRS

500 HRS

CHANGE

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

CHANGE

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

CHANGE-----

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

INSPECT

------

CHECK

------

CHECK

------

CHECK

TORQUE

*****

CHECK

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

CHECK

GREASE

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

GREASE

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

GREASE

-------------------------GREASE

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

CHECK

GREASE

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

GREASE

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

GREASE

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

GREASE

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

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

CHECK

GREASE

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

ANNUALLY

6 MO.

1500 HRS

1000 HRS

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

------

CHANGE CHANGE

------

CHANGE

------

CHANGE

------

CHANGE

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TYPE OR

EQUIVALENT

SAE 15W-40-CD *** DIESEL FUEL #2

MOBIL 424

ETHYLENE GLYCOL ANTI-FREEZE

MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY

MYSTIK TETRIMOLY

9141-3012

Located on right cab wall

P/N 9141-3012

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.

000850

Located on left side, front cab plate

P/N 9116-4094

Located on forward/reverse lever

P/N 9116-3028

Located on dash

Starting S/N 0160001286

P/N 9141-3061

Form No. 20027 • G6-42P Owner/Operator Manual

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.

9134-3016

Located on dashboard

w/ turbo option

P/N 9134-3016

2.2

OUTSIDE THE CAB

HYDRAULIC SYSTEM

FILL WITH TRACTOR HYDRAULIC FLUID

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

Genuine Parts

Located on frame below engine cover

P/N 9108-3492

or equivalent.

9114-3288

Located on frame below engine cover

P/N 9114-3288

LEAD ACID BATTERIES PRODUCE FLAMABLE AND

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

EXPLOSIVE GASSES

WHEN CHECKING, TESTING, USING

ELECTRICAL SYSTEM

9114-3284

Located on engine cover

P/N 9114-3284

STAY CLEAR OF MOVING PARTS

WHILE ENGINE IS RUNNING. MOVING PARTS CAN CAUSE

SERIOUS INJURY.

9114-3281

Located on hydraulic fill cap

P/N 9140-3573

JUMP STARTING INSTRUCTIONS

WHEN JUMP STARTING MATERIAL HANDLER * NEVER ALLOW VEHICLES TO TOUCH * CONNECT THE POSITIVE (+) JUMPER CABLE TO

POSITIVE (+) POST OF DISCHARGED BATTERY

* CONNECT OPPOSITE END OF POSITIVE (+) JUMPER

CABLE TO POSITIVE (+) POST OF BOOSTER BATTERY

* CONNECT THE NEGATIVE (-) JUMPER CABLE TO

NEGATIVE (-) POST ON BOOSTER BATTERY

* CONNECT OPPOSITE END OF NEGATIVE (-) JUMPER

CABLE TO GROUND POINT ON MACHINE AWAY FROM

DISCHARGED BATTERY * FOLLOW STANDARD STARTING PROCEDURES * REMOVE CABLES IN REVERSE ORDER AFTER MACHINE

HAS STARTED

Located on engine cover

P/N 9114-3285

COOLING SYSTEM

IS PRESSURIZED.

REMOVE CAP SLOWLY.

HOT FLUID CAN CAUSE BURNS.

9114-3285

8060-3026

Located on engine cover

P/N 9114-3281

Located on radiator

P/N 8060-3026

2.3

ADD

CHECK OIL LEVEL WITH HANDLER LEVEL AND ALL CYLINDERS RETRACTED.

2.5 GALLON BETWEEN ADD AND FULL MARKS

FULL

HYDRAULIC

OIL LEVEL

9140-3569

OUTSIDE THE CAB

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

Located on mud guard

P/N 8060-3022

NEVER OPERATE MACHINE WITHOUT

CONSULTING PROPER CAPACITY CHART FOR THE

CARRIAGE/FORK COMBINATION BEING USED.

9132-3030

Located on mud guard

P/N 9132-3030

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 hydraulic reservoir

P/N 9140-3569

7733-3027

Located on left cab wall

P/N 7733-3027

DIESEL FUEL IS FLAMMABLE

EXTINGUISH ALL OPEN FLAME AND

SMOKING MATERIALS WHEN REFUELING

INJURY OR DEATH COULD RESULT

FROM FIRE.

9114-3286

Form No. 20027 • G6-42P Owner/Operator Manual

Located on left cab wall

P/N 9114-3283

BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.

Located on right and left rear frame,

Located on left cab wall

P/N 9114-3286

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.

9114-3282

engine cover and boom head

P/N 9114-3282

2.4

OUTSIDE THE CAB

EXHAUST SYSTEMS CAN BE HOT.

KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.

HOT EXHAUST COMPONENTS CAN CAUSE

SEVERE BURNS.

9114-3280

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED

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

FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

PERSONNEL WORK PLATFORM.

BEFORE OCCUPYING PERSONNEL WORK PLATFORM.

9055-3026 REV. A

Located on right rear frame

P/N 9114-3280

ATTACHMENT MUST BE SECURED TO MACHINE.

CHECK TO ASSURE QUICK SWITCH PLUNGER

PIN IS FULLY ENGAGED AND LOCKED AFTER

IF PLUNGER PIN IS NOT FULLY ENGAGED

AND LOCKED ATTACHMENT MAY FALL OFF

ATTACHMENT CHANGE.

CAUSING SERIOUS INJURY OR DEATH.

9114-3290

Located on left side of boom head

P/N 9114-3290

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

ATTACHMENT

SERIAL NUMBER

WEIGHT

CAPACITY

HYD. PRESSURE

DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL HANDLER/PERSONNEL WORK

PLATFORM CAPACITY CHART DISPLAYED IN CAB.

9055-3033

Located on boom head

P/N 9055-3026

Located on left side of boom

P/N 9100-3031

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

ATTACHMENT

SERIAL NUMBER

WEIGHT

CAPACITY

HYD. PRESSURE

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

Located on personnel work platform

P/N 9055-3033

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM.

READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL BEFORE LIFTING PERSONNEL.

DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.

WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN CAB WITH PERSONNEL

OPERATE CONTROLS LIGHTLY AND CAUTIOUSLY WHEN 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.

IN DIRECT LINE OF SIGHT.

9055-3027 REV. A

Located on mudguard

P/N 9055-3027

Located on attachment

P/N 9015-3001

PINCH POINT

KEEP OUT

REACHING INTO BOOM

HOLES AND OTHER PINCH

POINTS CAN CAUSE

SERIOUS INJURY

OR DEATH.

Located on boom

P/N 8060-3037

8060-3037-A

3.0

OPERATOR’S CAB

The standard cab permits vision from all sides and includes an overhead guard to provide protection from falling objects.

A fully-enclosed cab with windows and a lockable door is available as an option. The top half of the cab door must be secured in the fully-opened or closed position. The bottom half of the cab door can be secured in the closed position only. Be sure the door and window are fully secured when operating the handler.

The operator’s seat is equipped with a seat belt and includes fore and aft adjustment to compensate for variations in operator size. The adjustment release/lock is located on the side

of seat. Wear seat belt when operating

machine.

An optional windshield wiper/washer is available for use with enclosed cabs. A control switch is located on the 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

WARNING

Never operate the handler unless the overhead guard is in good condition.

WARNING

Any modification which adds weight to this machine must be approved by GRADALL to assure compliance with FOPS/ROPS certification for this cab/machine configuration.

NOTE!

Relevant S.A.E. Recommended Practices: S.A.E. J1040 for ROPS S.A.E. J231 for FOPS

FORWARD/NEUTRAL

REVERSE LEVER

HOURMETER

ATTACHMENT TILT/

MACHINE LEVEL

(STANDARD)

AUX CONTROL LEVER

(OPTIONAL)

SERVICE BRAKE/

INCHING TRAVEL PEDAL

Form No. 20027 • G6-42P Owner/Operator Manual

STEERING

WHEEL

PARK BRAKE

QUARTZ

000000

LEVEL

INDICATOR

SWITCH

FUEL

OIL

240

TEMP

VOLTS

100

WORK

OFF

RUN

ACC

START

IGNITION

TRAVEL

MACHINE MUST BE IN NEUTRAL AND PARK BRAKE ON

TO START

OIL PRESSURE/

COOLANT TEMP/

VOLTMETER/

FUEL GAUGE

48" & 72"

CARRAIGE

48" & 72"

CARRAIGE

48" & 72"

CARRAIGE

BOOM CONTROL

JOYSTICK

HORN BUTTON

CAPACITY CHARTS

IGNITION SWITCH

4x2/4x4 SWITCH

ACCELERATOR PEDAL

TRACTION LOCK SWITCH

3.1

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

decrease speed.

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; pull lever back to tilt up.

Attachment Tilt Switch (optional): Depress left side of switch to tilt down; depress right side of switch to tilt up.

Auxiliary Control Lever (optional): This lever is used to control optional hydraulic attachments. Follow decal instructions for lever/handler movements.

Auxiliary Light Switch (optional): This switch turns auxiliary lights on and off.

Boom Control Joystick: This joystick controls boom elevation and extension. Pull joystick back to raise boom; push joystick forward to lower boom. Move joystick to right to extend boom; move to left to retract boom. Speed of boom movement is proportional to joystick actuation and engine RPM.

Engine Coolant Temperature Gauge: This gauge displays engine coolant temperature.

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

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

push lever fully forward for forward travel; lift and pull lever fully backward for reverse travel. Move lever to centered position for “Neutral.”

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, the EMI Rough Terrain Forklift Safety Manual and the GRADALL Material Handler Safety Manual and view the GRADALL/EMI Operator Orientation Video.

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 roatation to “START” engages starter motor. Counter-clockwise rotation to “OFF” stops engine and removes voltage from all electrical functions.

Level Indicator: This bubble level indicator enables the operator to determine the left to right level condition of the handler.

Lights Switch (optional): This switch controls optional lighting which may be provided with the handler.

Machine Level Lever: This lever controls the relationship of the handler frame to the front axle. Move the lever left to tilt frame to left, move the lever right to tilt frame to right.

Parking Brake Switch: This switch controls the application and release of the parking brake. Indicator light on switch glows (red) to indicate brake is applied.

+ 36 hidden pages

Gradall G6-42P Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

IMPORTANT SAFETY NOTICE

REVISIONS

TABLE OF CONTENTS

INTRODUCTION

NOMENCLATURE

SAFETY

DECALS