JLG G6-42A Operator Manual

0 (0)
Operation & Safety
Manual
Keep this manual with machine at all times.
Model
G6-42P
S/N 0160004018 & After
31200148
November 25, 2008
An Oshkosh Corporation Company
CALIFORNIA PROPOSITION 65
BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemical known to the
State of California
to cause cancer and
reproductive harm.
WASH HANDS
AFTER HANDLING!
CALIFORNIA PROPOSITION 65
EXHAUST 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.

Revision Log

Revision Log
November 25, 2008 - A - Original Issue of Manual
REVISION LOG
a31200148

Read This First

Read This First
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
Operator Qualifications
The operator of the machine must not operate the machine until this manual has been read, training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator. Operation within the U.S.A. requires training per OSHA 1910.178.
Operators of this equipment must possess a valid, applicable driver’s license, be in good physical and mental condition, have normal reflexes and reaction time, good vision and depth perception and normal hearing. Operator must not be using medication which could impair abilities nor be under the influence of alcohol or any other intoxicant during the work shift.
In addition, the operator must read, understand and comply with instructions contained in the following material furnished with the material handler:
• This Operation & Safety Manual
• Telehandler Safety Manual (as required)
• 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.
Modifications
Any modification to this machine must be approved by JLG.
b 31200148
Read This First
This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local authorized JLG representative for information regarding safety­related bulletins which may have been issued for this product.
JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.
JLG Industries, Inc. must be notified immediately in all instances where JLG products have been involved in an accident involving bodily injury or death of personnel or when damage has occurred to personal property or the JLG product.
FOR:
• Accident Reporting and Product Safety Publications
• Current Owner Updates
• Questions Regarding Product Applications and Safety
• Standards and Regulations Compliance Information
• Questions Regarding Product Modifications
CONTACT:
Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza
Hagerstown, MD 21742 USA
or Your Local JLG Office (Addresses on back cover)
In USA:
Toll Free: 1-877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: +1-717-485-5161 E-mail: ProductSafety@JLG.com
Other Publications Available
Service Manual .............................................................91404002
Illustrated Parts Manual.................................................91404001
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Table of Contents

TABLE OF CONTENTS
Revision Log
Read This First
Operator Qualifications ...................................................... b
Modifications ...................................................................... b
Other Publications Available .............................................. c
Table of Contents
Section 1 - General Safety Practices
1.1 Hazard Classification system...............................................1-1
Safety Alert System and Safety Signal Words................1-1
1.2 General Precautions ............................................................1-1
1.3 Operation Safety..................................................................1-2
Electrical Hazards ...........................................................1-2
Tip Over Hazard..............................................................1-3
Travel Hazard .................................................................1-6
Load Falling Hazard ........................................................1-7
Lifting Personnel .............................................................1-8
Driving Hazards on Slopes .............................................1-9
Pinch Points and Crush Hazards ..................................1-10
Fall Hazard....................................................................1-12
Chemical Hazards.........................................................1-13
Table of Contents
Section 2 - Pre-Operation and Inspection
2.1 Pre-Operation Check and Inspection...................................2-1
2.2 Safety Decals.......................................................................2-3
2.3 Walk-Around Inspection.......................................................2-6
2.4 Warm-Up and Operational Checks ...................................... 2-8
Warm-Up Check .............................................................2-8
Operational Check ..........................................................2-8
2.5 Operator Cab .......................................................................2-9
2.6 Windows ............................................................................2-10
Cab Door Window (if equipped)....................................2-10
Section 3 - Controls and Indicators
3.1 General ................................................................................3-1
3.2 Controls ...............................................................................3-2
Transmission Control Lever ............................................3-3
Ignition Switch .................................................................3-4
Boom Joystick .................................................................3-5
Attachment Tilt and Frame Sway Lever ..........................3-6
Auxiliary Control Joystick (if equipped) ...........................3-7
Dash Controls and Indicators.......................................... 3-8
Park Brake Switch........................................................... 3-9
i31200148
Table of Contents
Parking Procedure.......................................................... 3-9
Heater........................................................................... 3-10
3.3 Operator Seat.................................................................... 3-11
Seat Adjustments ......................................................... 3-11
Seat Belt ....................................................................... 3-13
3.4 Boom Angle and Extension Indicators .............................. 3-14
3.5 Mirror................................................................................. 3-14
Section 4 - Operation
4.1 Engine ................................................................................. 4-1
Starting the Engine ......................................................... 4-1
Cold Weather Starting Aids ............................................ 4-2
Battery Boosted Starting................................................. 4-3
Normal Engine Operation ............................................... 4-4
Shut-Down Procedure .................................................... 4-4
4.2 Operating with a Load ......................................................... 4-5
Lift Load Safely............................................................... 4-5
Picking Up a Load .......................................................... 4-5
Transporting the Load .................................................... 4-6
Leveling Procedure......................................................... 4-6
Placing the Load............................................................. 4-7
Disengaging the Load..................................................... 4-7
4.3 Operating with a Suspended Load ...................................... 4-8
Lift Load Safely............................................................... 4-8
Picking Up a Suspended Load ....................................... 4-8
Transporting a Suspended Load .................................... 4-9
Leveling Procedure......................................................... 4-9
Placing a Suspended Load........................................... 4-10
Disengaging a Suspended Load .................................. 4-10
4.4 Loading and Securing for Transport.................................. 4-11
Tiedown ........................................................................ 4-11
Lifting ............................................................................ 4-12
Section 5 - Attachments
5.1 Approved Attachments ........................................................ 5-1
5.2 Unapproved Attachments.................................................... 5-2
5.3 Telehandler/Attachment/Fork Capacity ............................... 5-3
5.4 Use of the Capacity Chart ................................................... 5-4
Capacity Indicator Locations .......................................... 5-4
Sample Capacity Chart................................................... 5-5
Example.......................................................................... 5-6
5.5 Attachment Installation ........................................................ 5-7
5.6 Adjusting/Moving Forks ....................................................... 5-9
5.7 Attachment Operation ....................................................... 5-10
Carriage w/Forks .......................................................... 5-11
ii 31200148
Crane Hook...................................................................5-12
Bucket ...........................................................................5-14
Truss Boom...................................................................5-16
Boom Head-Mounted Winch.........................................5-18
6 ft (1,8 m) Mast with 48 or 72 in (1,2 & 1,8 m)
Carriage ........................................................................5-19
6 ft (1,8 m) - 100° Swing Mast W/Side Shift..................5-21
Swing Carriage .............................................................5-23
Side Tilt Carriage ..........................................................5-25
Personnel Work Platform ..............................................5-27
Section 6 - Emergency Procedures
6.1 Towing a Disabled Product ..................................................6-1
Moving Short Distances ..................................................6-1
Moving Longer Distances ...............................................6-1
6.2 Emergency Lower of Boom..................................................6-2
6.3 Emergency Exit from Enclosed Cab ....................................6-2
Section 7 - Lubrication and Maintenance
7.1 Introduction ..........................................................................7-1
Clothing and Safety Gear................................................ 7-1
7.2 General Maintenance Instructions .......................................7-2
7.3 Service and Maintenance Schedules...................................7-3
10 & 1st 50 Hour Maintenance Schedule .......................7-3
50, 250 & 500 Hour Maintenance Schedule ...................7-4
1000 & 1500 Hour Maintenance Schedule .....................7-5
7.4 Lubrication Schedules .........................................................7-6
50 Hour Lubrication Schedule.........................................7-6
250 Hour Lubrication Schedule....................................... 7-7
7.5 Operator Maintenance Instructions......................................7-8
Fuel System ....................................................................7-8
Air Intake System ..........................................................7-10
Engine Oil ..................................................................... 7-12
Hydraulic Oil.................................................................. 7-13
Tires ..............................................................................7-14
Hydraulic Return Filter ..................................................7-17
Engine Cooling System................................................. 7-18
Battery........................................................................... 7-19
Table of Contents
Section 8 - Additional Checks
Section 9 - Specifications
9.1 Product Specifications .........................................................9-1
Fluid and Lubrication Capacities ..................................... 9-1
Tires ................................................................................9-2
Performance ...................................................................9-2
iii31200148
Table of Contents
Dimensions..................................................................... 9-3
Index
Inspection, Maintenance and Repair Log
iv 31200148

Section 1 - General Safety Practices

SECTION 1 - GENERAL SAFETY PRACTICES

1.1 HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a potentiality hazardous situation which, if not avoided, may result in minor or moderate injury.
OW0010
OW0021
OW0031

1.2 GENERAL PRECAUTIONS

WARNING
Before operation, read and understand this manual. Failure to comply with the safety precautions listed in this manual could result in machine damage, property damage, personal injury or death.
1-131200148
Section 1 - General Safety Practices

1.3 OPERATION SAFETY

Electrical Hazards

10 FT
(3 M)
OW0040
• This machine is not insulated and does not provide protection from contact or being near electrical current.
NEVER operate the telehandler in an area where overhead power lines, overhead or underground cables, or other power sources may exist without ensuring the appropriate power or utility company de-energizes the lines.
• Always check for power lines before raising the boom.
• Follow employer, local and governmental regulations for clearance from powerlines.
1-2 31200148
Section 1 - General Safety Practices

Tip Over Hazard

General
• For additional load requirements, refer to the appropriate capacity chart.
OW0050
• Never use an attachment without the appropriate JLG approved capacity chart installed on the telehandler.
• Understand how to properly use the capacity charts located in cab.
DO NOT exceed rated lift capacity.
• Be sure that the ground conditions are able to support the machine.
OW0080
DO NOT raise boom unless frame is level (0 degrees), unless otherwised noted on capacity chart.
4 FT
(1,2 M)
OW0100
DO NOT level machine with boom/attachment above 4 ft (1,2 m). (AUS - DO NOT level machine with load more than 11.8 in. (300 mm) above ground surface).
1-331200148
Section 1 - General Safety Practices
OH2291
MAINTAIN proper tire pressure at all times. If proper tire pressures are not maintained, this machine could tip over.
• Refer to manufacturer’s specifications for proper fill ratio and pressure requirements for tires equipped with ballast.
OH20911
• Always wear the seat belt.
• Keep head, arms, hands, legs and all other body parts inside operator’s cab at all times.
OH2221
If the telehandler starts to tip over:
DO NOT JUMP
• BRACE YOURSELF and STAY WITH THE MACHINE
• KEEP YOUR SEAT BELT FASTENED
•HOLD ON FIRMLY
• LEAN AWAY FROM THE POINT OF IMPACT
1-4 31200148
Non-Suspended Load
•DO NOT drive with boom raised.
Suspended Load
Section 1 - General Safety Practices
OW0060
OW0150
• Tether suspended loads to restrict movement.
DO NOT raise the load more than 11.8 in (300 mm) above ground surface or the boom more than 45°.
• Weight of all rigging (slings, etc.) must be included as part of load.
• Start, travel, turn and stop slowly to prevent load from swinging.
• When driving with the boom raised, DO NOT exceed walking speed.
• Beware of wind. Wind can cause a suspended load to swing and cause dangerous side loads - even with tag lines.
DO NOT attempt to use telehandler frame-leveling to compensate for load swing.
• Keep heavy part of load closest to attachment.
• Never drag the load; lift vertically.
1-531200148
Section 1 - General Safety Practices

Travel Hazard

4-Wheel Steer Pivot Steer
OW0120
• Steering characteristics differ between 4-Wheel Steer & Pivot Steer telehandlers as shown above. Identify the telehandler you are operating & others on the jobsite.
• Ensure that adequate clearance is provided between both rear tail swing and front fork swing.
• Unlike a conventional 4-wheel steer telehandler the rear wheels of a pivot steer telehandler turn a wider circle than the front wheels.
• Look out for and avoid other personnel, machinery and vehicles in the area. Use a spotter if you DO NOT have a clear view.
• Before moving be sure of a clear path and sound horn.
• When driving, retract boom and keep boom/attachment as low as possible while maintaining visibility of mirrors and maximum visibility of path of travel.
• Always look in the direction of travel.
• Always check boom clearances carefully before driving underneath overhead obstructions. Position attachment/load to clear obstacles.
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Section 1 - General Safety Practices

Load Falling Hazard

OW0130
• Never suspend load from forks or other parts of carriage.
DO NOT burn or drill holes in fork(s).
• Forks must be centered under load and spaced apart as far as possible.
1-731200148
Section 1 - General Safety Practices

Lifting Personnel

OW0170
• When lifting personnel, USE ONLY a JLG approved personnel work platform, with proper capacity chart displayed in the cab.
OW0190
DO NOT drive machine from cab when personnel are in platform.
1-8 31200148
Section 1 - General Safety Practices

Driving Hazards on Slopes

OW0200
To maintain sufficient traction and braking capabilities, travel on slopes as follows:
• When unloaded, the rear of the machine is the “heavy end.” Drive with forks pointed downhill.
• When loaded, the front of the machine is the “heavy end.” Drive with the forks pointed uphill.
• For additional travel requirements, refer to the appropriate capacity chart.
• To avoid overspeeding the engine and drivetrain when driving down 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.
• Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT drive across excessively steep slopes under any circumstances.
• Avoid turning on a slope. Never engage “inching” or shift to “Neutral” when going downhill.
DO NOT park on a slope.
1-931200148
Section 1 - General Safety Practices

Pinch Points and Crush Hazards

Stay clear of pinch points and rotating parts on the telehandler.
• Stay clear of moving parts while engine is running.
OW0220
• Keep clear of steering tires and frame or other objects.
OW0210
OW0230
• Keep clear from under boom.
1-10 31200148
Section 1 - General Safety Practices
OW0240
• Keep clear of boom holes.
OW0250
• Keep arms and hands clear of attachment tilt cylinder.
OW0260
• Keep hands and fingers clear of carriage and forks.
OW0960
• Keep others away while operating.
1-1131200148
Section 1 - General Safety Practices

Fall Hazard

OW0280
• Enter using the proper hand holds and steps provided. Always maintain 3-point contact when mounting or dismounting. Never grab control levers or steering wheel when mounting or dismounting the machine.
DO NOT get off the machine until the shutdown procedure on page 4-4 has been performed.
OW0290
DO NOT carry riders. Riders could fall off machine causing death or serious injury.
1-12 31200148
Section 1 - General Safety Practices

Chemical Hazards

Exhaust Fumes
DO NOT operate machine in an enclosed area without proper ventilation.
DO NOT operate the machine in hazardous environments unless approved for that purpose by JLG and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion.
• If spark arrestors are required, ensure they are in place and in good working order.
Flammable Fuel
OW0300
DO NOT fill the fuel tank or service the fuel system near an open flame, sparks or smoking materials. Engine fuel is flammable and can cause a fire and/or explosion.
Hydraulic Fluid
OW0950
DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure.
• Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under enough pressure that it can penetrate the skin.
DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to protect hands from spraying fluid.
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Section 1 - General Safety Practices
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1-14 31200148

Section 2 - Pre-Operation and Inspection

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1 PRE-OPERATION CHECK AND INSPECTION

Note: Complete all required maintenance before operating unit.
WARNING
FALL HAZARD. Use extreme caution when checking items beyond your normal
reach. Use an approved ladder.
The pre-operation check & inspection, performed at beginning of each work shift or at each change of operator, should include the following:
1. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.
2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.
OAH1000
PARENT METAL CRACK WELD CRACK
3. Safety Decals - Ensure all safety decals are legible and in place. Clean or replace as required. See page 2-3 for details.
4. Operation and Safety Manuals - Operation and Safety Manual and AEM Safety Manual (as required) are located in cab manual holder.
5. Walk-Around Inspection - See page 2-6 for details.
6. Fluid Levels - Check fluids, including fuel, hydraulic oil, engine oil and coolant. When adding fluids, refer to Section 7 - Lubrication and Maintenance and Section 9 - Specifications to determine proper type and intervals. 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.
7. Attachments/Accessories - Ensure correct load charts are installed on the telehandler. If provided, reference the Operation and Safety Manual of each attachment or accessory installed for specific inspection, operation and maintenance instructions.
2-131200148
Section 2 - Pre-Operation and Inspection
8. Operational Check - Once the walk-around inspection is complete, perform a warm-up and operational check (see page 2-8) of all systems in an area free of overhead and ground level obstructions. See Section 3 - Controls and Indicators for more specific operating instructions.
WARNING
If telehandler does not operate properly, immediately bring machine to a stop, lower boom and attachment to ground and stop the engine. Determine cause and correct before continued use.
2-2 31200148
Section 2 - Pre-Operation and Inspection

2.2 SAFETY DECALS

Ensure all DANGER, WARNING, CAUTION and instructional decals and proper capacity charts are legible and in place. Clean and replace as required.
Model
Year of Manufacture
Serial Number
Maximim Capacity (lbs/kg)*
1705881
(After S/N
0160022389)
Maximum Weight Without Attachments (lbs/kg)
Refer to load capacity chart for truck with attachment, and individual load ratings stamped on forks, if equipped. Use lowest capacity of all rattings.
As released from factory this truck meets design specifications in ASME B56.6-2002 Part III
One or more of the following patents may apply to this truck: U.S. Nos. 4,954,041 6,349,969 5,639,119 5,813,697 5,230,399 5,052,532. Other patents pending.
Manufactured by JLG Industries Inc. McConnellsburg, PA 17233-9533 USA
1705882
(Before S/N
0160022389)
NO RIDERS PERMITTED ON HANDLER.
OPERATOR ONLY IN MACHINE
WHILE RUNNING.
RIDERS COULD FALL OFF MACHINE
1705882
CAUSING SERIOUS INJURY OR DEATH.
9114-3283
91143283
DIESEL FUEL IS FLAMMABLE
EXTINGUISH ALL OPEN FLAME AND
SMOKING MATERIALS WHEN REFUELING
INJURY OR DEATH COULD RESULT
FROM FIRE.
91143286
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
9114-3286
CAUSE SERIOUS INJURY OR DEATH.
9114-3282
91143282
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.
91343016
A
91503102
9134-3016
9150-3102 REV. -
WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM.
WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN CAB WITH 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.
B
A
READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.
DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.
IN DIRECT LINE OF SIGHT.
OPERATE CONTROLS LIGHTLY AND CAUTIOUSLY WHEN LIFTING PERSONNEL.
FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.
90553027
91323030
NEVER OPERATE MACHINE WITHOUT
CONSULTING PROPER CAPACITY CHART FOR THE
CARRIAGE/FORK COMBINATION BEING USED.
9132-3030
90553028
FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF
SERIOUS INJURY, READ AND OBSERVE THE FOLLOWING:
15. BEFORE ADJUSTING OR SERVICING, PLACE
7. WHEN TRAVELING WITH LOAD, FULLY RETRACT BOOM AND
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.
91413012
GRADALL HANDLER SERVICE INSTRUCTIONS FOR: G6-42P
DIESEL ENGINE AIR CLEANER ELEMENT--------------**--------------------------------------------­FUEL FILTERS--------------------------------------
B
C
OIL FILTER--------------------------------­OIL (14.5 QT.) (13.6 LTR.)----­DIESEL FUEL (38 GAL.) (143.8 LTR.) HYDRAULIC SYSTEM 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
AT FULL THROTTLE AND AT OPERATING TEMPERATURE. ** CHECK AIR CLEANER RESTRICTION INDICATOR. CLEAN OR CHANGE PRIMARY FILTER IF NECESSARY.
SAFETY ELEMENT TO BE CHANGED EVERY 3RD CHANGE OF PRIMARY FILTER ELEMENT.
*** CONSULT DEALER FOR RECOMMENDATIONS AT EXTREME TEMPERATURES.
**** DAILY SERVICE MAY BE REQUIRED FOR OPTIMUM LIFE DEPENDING UPON APPLICATION SEVERITY. *****IF COOLANT IS ADDED TO RADIATOR ADD 3% SCA BY VOLUME.
IT IS RECOMMENDED THAT FILTER ELEMENTS, FRONT AXLE LUBRICANT, AND ENGINE OIL BE CHANGED AFTER FIRST 100 HRS ON NEW OR REBUILT UNITS.
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.
SERVICE INTERVALS
DAILY
WEEKLY
EVERY
3 MO.
OR
OR
5WKS OR
OR
10 HRS
50 HRS
250 HRS
500 HRS
CHANGE
-------------------
CHANGE
-------------------
CHANGE-----
CHECK
--------------------------------
FILL
CHECK
INSPECT
------
------------­CHECK
------
------------­CHECK
------
-------------
------
CHECK
-------------------
TORQUE
------ --------------------------
*****
CHECK
--------------------------
CHECK GREASE
--------------------------
GREASE
--------------------------
GREASE
-------------------------­GREASE
--------------------------
CHECK
GREASE
-------------------
GREASE
--------------------------
GREASE
--------------------------
GREASE
--------------------------
-------------------
CHECK
--------------------------
GREASE
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
ANNUALLY
6 MO.
TYPE OR
OR
OR
EQUIVALENT
1500 HRS
1000 HRS
-------------
SAE 15W-40-CD *** DIESEL FUEL #2
MOBIL 424
------
CHANGE CHANGE
------
CHANGE
MOBIL 424
------
CHANGE
------
-----­MOBIL 424
CHANGE
-------------
ETHYLENE GLYCOL ANTI-FREEZE
MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
9141-3012
C
91323030
NEVER OPERATE MACHINE WITHOUT
CONSULTING PROPER CAPACITY CHART FOR THE
CARRIAGE/FORK COMBINATION BEING USED.
9132-3030
9055-3027 REV. A
80603022
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
OY1061
VIEW A-A
2-331200148
Section 2 - Pre-Operation and Inspection
91143282
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.
91163028
91413061
91143280
BEFORE
S/N 0160026801
EXHAUST SYSTEMS CAN BE HOT.
KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.
HOT EXHAUST COMPONENTS CAN CAUSE
SEVERE BURNS.
9114-3280
9114-3282
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.
9114-3282
91143282
91143285
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
91083492
9114-3285
91143281
STAY CLEAR OF MOVING PARTS
WHILE ENGINE IS RUNNING. MOVING PARTS CAN CAUSE
SERIOUS INJURY.
Genuine Parts
HYDRAULIC SYSTEM
FILL WITH TRACTOR HYDRAULIC FLUID
R
or equivalent.
For Mobil Product Information, Call 1-800-662-4525.
91143288
91403573
9114-3281
DD
* 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
9114-3288
LEAD ACID BATTERIES PRODUCE FLAMABLE AND
EXPLOSIVE GASSES
WHEN CHECKING, TESTING, USING
BOOSTER BATTERY OR CHARGING BATTERIES:
RESULT IN SERIOUS INJURY OR DAMAGE TO THE
ELECTRICAL SYSTEM
3
7
5 3
-
0 4
1
9
91403569
FULL
ADD
HYDRAULIC OIL LEVEL
CHECK OIL LEVEL WITH HANDLER LEVEL AND ALL CYLINDERS RETRACTED.
2.5 GALLON BETWEEN ADD AND FULL MARKS
9140-3569
9114-3284
91143284
9151-3207 REV.-
VIEW B-B
91403529
TRACTION LOCK
LOCKS FRONT & REAR AXLES
HYDRAULICALLY FOR INCREASED
TRACTION. DO NOT USE ON
IMPROVED SURFACES.
MACHINE MUST BE IN 4X4
MODE.
9140-3529
80603026
COOLING SYSTEM IS PRESSURIZED.
REMOVE CAP SLOWLY.
HOT FLUID CAN CAUSE BURNS.
8060-3026
+
VIEW C-C VIEW D-D
91413024
FORWARD DRIVE PRESSURE TEST PORT
REVERSE DRIVE PRESSURE TEST PORT
CHARGE PRESSURE TEST PORT
IMPLEMENT PRESSURE TEST PORT
9141-3024 (-)
OY1071
VIEW OF HYDRAULIC TANK
2-4 31200148
Safety Decals 3
Section 2 - Pre-Operation and Inspection
B
9114-3282
80603037
PINCH POINT
KEEP OUT
REACHING INTO BOOM
HOLES AND OTHER PINCH
POINTS CAN CAUSE
SERIOUS INJURY
OR DEATH.
8060-3037-A
B
91143282
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING. BEING IN PINCH POINT AREA COULD CAUSE SERIOUS INJURY OR DEATH.
4105262
0
8
0
7
60
50
40
20
0
9114-3282
30
-10
10
A
80°
70°
° 0 6
° 0 5
° 0 4
° 0 3
20°
10°
-1 0
°
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.
91143290
A
91513210
PINCH POINT
KEEP OUT
REACHING INTO BOOM
HOLES AND OTHER PINCH
POINTS CAN CAUSE
SERIOUS INJURY
OR DEATH.
9114-3290
91513210
PINCH POINT
KEEP OUT
REACHING INTO BOOM
HOLES AND OTHER PINCH
POINTS CAN CAUSE SERIOUS INJURY
OR DEATH.
8060-3037-A
91143282
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
8060-3037-A
CAUSE SERIOUS INJURY OR DEATH.
91513210
READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.
WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED
PERSONNEL WORK PLATFORM.
ALL PERSONNEL IN PLATFORM MUST WEAR A FULL BODY HARNESS WITH
LANYARD ATTACHED TO A DESIGNATED ANCHORAGE POINT.
READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL
BEFORE OCCUPYING PERSONNEL WORK PLATFORM.
FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.
9055-3026 REV. A
VIEW A-A
91513210
PINCH POINT
KEEP OUT
REACHING INTO BOOM
HOLES AND OTHER PINCH
POINTS CAN CAUSE SERIOUS INJURY
OR DEATH.
VIEW B-B
8060-3037-A
OY1250
2-531200148
Section 2 - Pre-Operation and Inspection

2.3 WALK-AROUND INSPECTION

16
1
2
3
4
5
6
7
8
9
Begin your walk-around inspection at item 1, as noted below. Continue to your right (counterclockwise when viewed from top) checking each item in sequence.
INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned. Inspect all structural members including attachment for cracks, excessive corrosion and other damage.
15
14
13
12
11
10
OY0181
1. Boom Sections & Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders
• Check front, top, side & rear slider pads for adequate grease.
• Pivot pins secure; hydraulic hoses undamaged, not leaking.
• Check extend/retract cables and adjustment blocks for adequate tension.
2. Front Axle
3. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepancies.
- Pivot pins secure; hydraulic hoses undamaged, not leaking.
-
2-6 31200148
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